Reduced fat chocolate

Abstract

To provide a reduced fat chocolate composition and a method of manufacturing a reduced fat chocolate composition, and particularly to provide a healthier, lower cost alternative to chocolate.SOLUTION: There is provided a reduced fat chocolate composition comprising: a continuous fat phase, the fat phase comprising a fat and an emulsifier; and at least two particulate materials distributed throughout the fat phase, wherein the at least two particulate materials have different D50 particle sizes to each other, and the difference is 6 to 8 times.SELECTED DRAWING: None

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of European Patent Application No. 20176979.1, entitled "REDUCED FAT CHOCOLATE," filed May 28, 2020, which is incorporated by reference in its entirety.

[0002] FIELD OF THEINVENTION The present invention relates to reduced-fat chocolate compositions and methods of making reduced-fat chocolate compositions. In particular, the present invention relates to reduced-fat chocolate compositions having a greater maximum fill factor than comparable conventionally produced chocolates while having substantially the same viscosity as comparable conventionally produced chocolates to provide a healthier, lower cost alternative. [Background technology]

[0003] Increasing consumer preferences for "healthier" foods, including chocolate products that contain less fat and / or calories than traditional foods, have created a high demand for reduced-fat and reduced-calorie alternatives.

[0004] The fat in chocolate typically comprises or consists of cocoa fat, which is usually the most expensive of all chocolate ingredients. Conventional full-fat chocolate typically contains a total fat content of at least 23% by weight, but this can vary significantly depending on the chocolate application. By reducing the amount of cocoa fat used to make chocolate products, manufacturers can achieve cost savings. However, it is difficult to reduce the amount of fat without adversely affecting the rheological and / or sensory (e.g., mouthfeel) properties of the chocolate.

[0005] The viscosity of chocolate is important for its intended use. Generally speaking, the less fat the chocolate contains, the thicker and more viscous the molten chocolate will be. This may be suitable for extrusion applications, but may not be suitable for enrobing or molding applications, for example, as it will be difficult to process. For example, if the chocolate is too thick, it is mechanically difficult to apply a thin coating of chocolate to a confectionery product, and air bubbles may not rise from the viscous chocolate before hardening occurs, thereby negatively affecting the appearance and texture of the final product.

[0006] Emulsifiers and / or surfactants are generally added to chocolate to enhance its rheological properties. These emulsifiers help coat the solid particles in the chocolate, allowing them to flow, thereby allowing a partial reduction in fat content, since the emulsifiers perform part of the function of fat. However, the amount of emulsifier that can be used is limited. Higher dosages of emulsifiers can cause off-flavors and difficulties in processing the chocolate. In some jurisdictions, there are also legal limits on the amount of emulsifier that can be used. Some examples of emulsifiers typically used in chocolate are lecithin, which is produced from soybeans, sunflowers or rapeseed, ammonium phosphatide, and poly glycerol poly ricinoleic acid (PGPR). Emulsifiers can also be selected, for example, to produce specially shaped confections or to reduce the formation of white mold-like spots on the chocolate, known as chocolate bloom.

[0007] Chocolate is a dispersion of solid particles (e.g. sugar, milk powder, and cocoa solids) in a continuous fat phase. The effect of the particle size distribution of these solid particles on the rheological properties of chocolate has been investigated before. For example, EP 1061813 discloses a rheologically modified confectionery with a total fat content of 16-35%, produced by using a specific particle size distribution. The aim of EP 1061813 was to improve the packing density of the solid particles. However, the particle packing achieved was insufficient in nature, since the authors failed to take into account intrinsic characteristics such as particle shape. The maximum packing factor of the product described in EP 1061813, determined by the method described herein, is only approximately 0.54 (see Example 3 herein). This means that there is still a large space between the solid particles filled with expensive cocoa fat. As a result, the chocolate described therein is not cost-effective to produce and has poor rheological properties.

[0008] There remains a need for a reduced-fat chocolate that provides a healthy, low-cost alternative to conventional full-fat chocolate and avoids or ameliorates the above-mentioned drawbacks. The present invention aims to meet this need by adjusting the morphological parameters of the solid particles in the chocolate to allow for a reduction in fat content by increasing the solid phase volume while precisely controlling the rheological behavior of the chocolate. The compositions and methods described herein can be used to produce chocolate compositions suitable for a variety of applications. The compositions of the present invention have similar rheological properties as comparable conventional chocolate compositions, while offering advantageous reductions in fat and calories and reducing production costs. Summary of the Invention

[0009] In one aspect, the present invention provides a reduced-fat chocolate composition, the reduced-fat chocolate composition comprising: a continuous fat phase, said fat phase comprising a fat and an emulsifier; and at least two particulate ingredients distributed throughout the fatty phase; A reduced-fat chocolate composition, wherein at least two particulate ingredients have different D50 particle sizes, the difference being between 6 and 8 times.

[0010] The reduced-fat chocolate composition may have a solids volume, x, and a Bingham plastic viscosity value, y, of 40° C. or greater in Pa.s; x is 0.4 to 0.7; y<264x 3 -330x 2 +141x-20.

[0011] The reduced-fat chocolate composition may have a Bingham plastic viscosity value of from 0.1 to 10 Pa.s and a Bingham yield stress of from 1 to 150 Pa at 40°C.

[0012] The total fat content of the reduced-fat chocolate composition may be 31-33% for molding applications, 25-27% for extrusion applications, 37-40% for enrobing applications, or 44-46% for ice cream dipping applications.

[0013] In another aspect, the present invention provides a food product comprising a reduced-fat chocolate composition according to the present invention.

[0014] In a further aspect, the present invention provides a method of preparing a reduced-fat chocolate composition, the method comprising: (a) a continuous fatty phase, said fatty phase comprising a fat and optionally an emulsifier; and providing an initial chocolate composition comprising at least two particulate ingredients distributed throughout the fat phase; (b) optionally measuring the maximum fill rate and viscosity of the initial chocolate composition; (c) preparing a reduced-fat version of the initial chocolate composition, the preparing comprising: i. determining optimized particle packing parameters for at least two particulate ingredients of the initial chocolate composition, the optimized particle packing parameters being optimized such that the reduced-fat chocolate composition has a maximum packing value that is greater than a maximum packing value of the initial chocolate composition and a viscosity that is substantially the same as a viscosity of the initial chocolate composition; ii. selecting at least two particulate ingredients for the reduced-fat chocolate composition that are identical to the at least two particulate ingredients of the initial chocolate composition but with optimized particle packing parameters; iii. combining the selected particulate ingredients with a fat phase and emulsifiers that are identical to the fat phase and emulsifiers of the initial chocolate composition to provide a reduced-fat version of the initial chocolate composition.

[0015] Particle packing parameters may include particle size distribution, particle shape, and / or relative amounts of at least two particulate materials.

[0016] The optimized particle loading parameters may be optimized such that the reduced-fat chocolate composition has a maximum loading percentage that is at least 1% greater than the maximum loading percentage of the initial chocolate composition.

[0017] Optimized particle packing parameters may be determined using mathematical modeling. Preferably, the mathematical model used is the compressible packing model described herein.

[0018] In another aspect, the present invention provides a reduced-fat chocolate composition obtained or obtainable by the process of the present invention.

[0019] The at least two particulate ingredients may be selected from the group consisting of sugar, cocoa solids, milk solids, bulking agents, calcium carbonate, nutritional particles, and flavorings, and / or mixtures of two or more thereof.

[0020] The fat in the fat phase may comprise or consist of cocoa butter, cocoa butter equivalents, cocoa butter substitutes, anhydrous milk fat, fractions thereof, and / or mixtures of two or more thereof.

[0021] The emulsifier may be selected from the group consisting of lecithin, soy lecithin, polyglycerol polyricinoleate (PGPR), ammonium phosphatide (AMP), sorbitan tristearate, sucrose polyerucate, sucrose polystearate, diacetyl tartaric acid mono-di-glyceride phosphate / monoglyceride. [Brief description of the drawings]

[0022] [Figure 1] 1 is a graph showing the relationship between viscosity and solid phase volume of a typical solution. [Diagram 2] FIG. 1 is a graph showing the relationship between viscosity and solid volume for formulation 1 (prior art) and formulations 2 and 3 (according to the invention) for different chocolate applications: extrusion, molding, enrobing and ice cream. [Diagram 3] FIG. 2 is a graph showing the relationship between viscosity and φ / φmax for formulation 1 (prior art) and formulations 2 and 3 (according to the invention) for different chocolate applications: extrusion, moulding, enrobing and ice cream. [Figure 4] PGPR flow curves for dark chocolate samples. [Diagram 5] PGPR flow curves for milk chocolate samples. [Figure 6] Representation of (a) loosening and (b) wall effects taken into account in the compressible packing model (CPM). [Figure 7] 1 is a graph showing the evolution of the hypothetical maximum packing fraction of a binary mixture. [Figure 8] 1 is a graph showing the particle size distribution of a typical cocoa powder having a maximum packing factor of 0.49. [Figure 9](a) A series of two graphs (a) and (b) illustrating the maximum packing fraction as a function of the shape factor β (b) particle aspect ratio, while the particle size distribution is kept constant (shown in FIG. 8). [Figure 10] 1 is a graph showing % fat reduction according to the present invention. [Figure 11] 1 is a graph showing % fat reduction according to the present invention. [Figure 12] 1 is a graph showing the correlation between viscosity and φ / φmax for known chocolates produced by Cargill. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] Unless otherwise specified, all terms should be given their technical meaning consistent with their ordinary meaning in the art as understood by those of ordinary skill in the art.

[0024] All ratios, amounts and percentages herein are by total weight of the reduced-fat chocolate composition unless otherwise specified.

[0025] All parameter ranges include the endpoints of the range and all values ​​between the endpoints, unless otherwise specified.

[0026] As used in this specification and claims, the terms "comprise" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted as excluding the presence of other features, steps or components.

[0027] Chocolate composition The present invention provides a method for preparing a reduced-fat chocolate composition. As used herein, the term "chocolate composition" refers to any composition comprising cocoa solids (as defined below) in any amount, although in some jurisdictions chocolate may be legally defined by the presence of a minimum amount of cocoa solids and / or compounds including cocoa butter or cocoa butter substitutes. Advantageously, the term chocolate composition refers to a composition that meets the legal definition of chocolate in any jurisdiction (preferably US and / or EU) and also includes any product (and / or components thereof) in which all or part of the cocoa butter is replaced by a cocoa butter equivalent, replacement or substitute. The term chocolate composition may also refer to chocolate compositions comprising cocoa butter and edible solids other than cocoa butter, as well as "chocolate-like" compositions including suspensions of edible solids in a continuous fat phase other than cocoa butter (e.g. Caramac®). The term chocolate composition may refer to whole food products and / or ingredients thereof. The chocolate may be dark, milk, white, ruby ​​or crumb chocolate, or variations thereof, as known to those skilled in the art. The chocolate composition may be suitable for a variety of applications, including, but not limited to, extruding, molding, enrobing, coating, dipping (e.g., for dipped ice cream), spraying, making chocolate bars, chunks, chips, clumps, vermicelli, and / or sprinkles.

[0028] The reduced-fat chocolate composition has a reduced fat content compared to the initial chocolate composition.

[0029] The initial chocolate composition is the starting material for the process of the present invention and may comprise any existing chocolate composition as defined above, which may be commercially available or specially prepared. The aim of the process is to obtain a reduced-fat chocolate composition that may be used as a low-fat substitute for the initial chocolate composition.

[0030] The reduced-fat chocolate composition obtained or obtainable by the process of the present invention comprises at least two particulate ingredients dispersed throughout a continuous fat phase, and an emulsifier. In molten form, the particulate ingredients are suspended in the fat phase of the composition, which is in a liquid state. Preferably, the particulate ingredients are substantially homogeneously distributed throughout the fat phase.

[0031] fat phase The fat phase of the reduced-fat chocolate composition may comprise any fat that is suitable for chocolate making, including, but not limited to, cocoa fat, cocoa fat substitutes (including equivalents, replacements, and substitutions), vegetable fat, anhydrous milk fat, fractions thereof, and / or mixtures of two or more thereof. The fat phase also comprises one or more emulsifiers. Preferably, the fat phase is composed of a fat and one or more emulsifiers that are suitable for chocolate making.

[0032] Non-limiting examples of suitable emulsifiers are lecithin, soy lecithin, polyglycerol polyricinoleate (PGPR), ammonium phosphatide (AMP), sorbitan tristearate, sucrose polyerucate, sucrose polystearate, diacetyl tartaric acid mono-di-glyceride phosphate / monoglyceride, or combinations thereof.

[0033] Preferably, the fat phase comprises cocoa butter, which is also referred to herein as "added cocoa butter" or "added fat" to distinguish it from cocoa butter that may be inherent in some cocoa solids-containing ingredients, as discussed below.

[0034] In one non-limiting example, the added cocoa fat is present in the chocolate composition in an amount of 0% to 40% by weight relative to the total weight of the chocolate composition, preferably 5% to 35%, more preferably 10% to 30%, more preferably 15% to 25%.

[0035] The total fat content of the reduced-fat chocolate composition includes added fat in the fat phase and any fat that may be part of the particulate ingredients (e.g. in full-fat cocoa powder). The total fat content of the reduced-fat chocolate composition according to the invention is up to 20% less than the total fat content of the initial chocolate composition, for example up to 15% less, or up to 10% less, or up to 5% less. In other examples, the total fat content of the reduced-fat chocolate composition according to the invention is 0.5% to 10% less than the fat content of the initial chocolate composition, or 1 to 3% less than the fat content of the initial chocolate composition. The total fat content of the reduced-fat chocolate composition according to the invention may be 20% or more by weight of the total reduced-fat chocolate composition, but still less than the total fat content of the initial chocolate composition. In one (non-limiting) example of a chocolate bar product according to the invention, the total fat content is 26% or less, preferably 25% or less, more preferably 24% or less.

[0036] particulate material The reduced-fat chocolate composition comprises at least two particulate ingredients dispersed (eg, homogeneously) throughout the fat phase.

[0037] The at least two particulate ingredients are selected from the group consisting of sugar, cocoa solids, milk solids, bulking agents, calcium carbonate, nutritional particles (e.g., vitamins, minerals, and / or dietary supplement compositions), flavors (e.g., vanilla, spices, coffee, salt, etc.), non-visible inclusions, and / or any other edible solid particles suitable for use in confectionery, and any combination thereof.

[0038] The term "sugar" as used herein refers to any type of sweetener containing a composition suitable for use in food.Non-limiting examples of sugars that can be used in the present invention include monosaccharides such as glucose, dextrose, fructose, allulose, or galactose, disaccharides such as sucrose, lactose, or maltose, polyols such as sorbitol, mannitol, maltitol, xylitol, erythritol, or isomalt, high-density sweeteners such as Stevia®, honey, agave syrup, maple syrup, and combinations of two or more thereof.

[0039] Advantageously, the sugar is sucrose. As used herein, the term "sucrose" includes various forms of sucrose, including, but not limited to, standard (e.g., granulated or crystalline) cooking sugar, powdered sugar, white sugar, confectioner's sugar, liquid sugar, silk sugar, raw sugar, cane sugar, and molasses.

[0040] Advantageously, the sugar is a composition comprising crystalline sugar dispersed in cocoa butter, hereafter called "sweet fat", prepared according to Example 1 below. The sweet fat is essentially a chocolate without cocoa or a non-dairy white chocolate.

[0041] In one non-limiting example, the chocolate composition comprises sugar in an amount of from 1% to 65% by weight, such as from 5% to 60% by weight, or from 10% to 55% by weight, or from 15% to 50% by weight, or from 20% to 45% by weight, or from 25% to 40% by weight, or from 30% to 35% by weight, based on the total weight of the chocolate composition. Preferably, sugar is present in an amount of from 40% to 60%, or preferably from 45% to 60%, or preferably from 50% to 55%.

[0042] As used herein, particle size (also called "particle size measurement") is defined using the D50 value. The D50 value is a common way of describing particle size distribution and is sometimes referred to as the "mean" or "statistical mean" particle size. "D50" refers to the value of the maximum particle dimension (e.g., the diameter of a typical spherical particle) below which 50% of the volume of the particles in the sample have a maximum particle dimension. In other words, in the cumulative distribution of maximum particle dimensions in a sample of particles, 50% of the distribution lies below the D50 value.

[0043] "Maximum dimension" or "maximum particle dimension" refers to the longest cross-sectional dimension of any particular particle, e.g., a cocoa solid particle or a sugar particle.

[0044] The D50 value can be measured using the methods described herein using a laser light diffraction / scattering particle size analyzer (e.g., a Malvern Mastersizer 3000 sold by Malvern Panalytical Ltd.), or using other known methods.

[0045] The sugar used in the present invention may be "raw sugar" having a D50 particle size of more than 50 μm, or it may be "refined sugar" having a D50 particle size of 1 μm to 15 μm, or preferably 7 μm to 13 μm, or preferably 8 μm to 12 μm, or preferably about 10 μm. In a preferred embodiment, the refined sugar is sugar in the form of a sweet fat (as defined above) having a D50 particle size of 9 μm to 11 μm. In some examples, the sugar may have a bimodal particle size distribution. In that case, the D50 values ​​above may apply to only one of the distributions.

[0046] As used herein, "cocoa solids" refers to solid cocoa particles. Preferably, the cocoa solids used will be cocoa powder, or cocoa solids containing ingredients such as cocoa liquor or cocoa mass. In the case of such cocoa solids-containing ingredients, the term cocoa solids refers only to the solid cocoa particles and not to any surrounding fat that may also be present in the ingredient. Preferably, the cocoa solids are standard cocoa powder (having a fat content of 10-12%), reduced-fat or defatted cocoa powder (e.g. produced using solvent extraction), or cocoa liquor.

[0047] In one non-limiting example, cocoa solids may be present in the reduced fat chocolate composition in an amount from 5% to 40% by weight, or preferably from 15% to 25% by weight, or preferably about 20% by weight, based on the total weight of the chocolate composition.

[0048] The cocoa solids may be "coarse cocoa solids" having a D50 particle size of 5 μm to 15 μm, or preferably 7 μm to 13 μm, or preferably 8 μm to 12 μm, or preferably about 10 μm. Alternatively, the cocoa solids may be "fine cocoa solids" having a D50 particle size of 0.5 μm to 4 μm, or preferably 1 to 3 μm, or about 2 μm. In some instances, the cocoa solids may have a bimodal particle size distribution. In that case, the D50 values ​​above may apply to only one of the distributions.

[0049] Refined sugar and / or fine cocoa solids may be commercially available or they may be produced in a preliminary step of the claimed method by applying known processes such as grinding, micronization, or the like of raw sugar or cocoa solids.

[0050] "Bulking agents", also known as "fillers", may be used as particulate materials to affect the organoleptic or rheological properties of the chocolate composition. Any suitable bulking agent known in the art, including soluble and / or insoluble fibers, may be used in accordance with the present invention. Non-limiting examples of "insoluble fibers" that may be used in accordance with the present invention are dietary fibers, cereal fibers, and / or other vegetable fibers. Non-limiting examples of "soluble fibers" that may be used in accordance with the present invention are resistant dextrin, resistant / modified maltodextrin, polydextrose, β-glucan, galactomannan, fructooligosaccharides, glucooligosaccharides, galactooligosaccharides, MOS (mannose oligosaccharides, also known as mannan oligosaccharides or mannooligosaccharides), pectin, psyllium, inulin, and resistant starch.

[0051] According to the invention, the at least two particulate materials have different D50 particle sizes from each other. Preferably, the difference is 3 to 12 times, preferably 5 to 10 times, more preferably 6 to 8 times, more preferably 7 times. In one example, the larger D50 particle size of the at least two particulate materials is at least 7 times larger than the smaller D50 particle size of the at least two particulate materials. In another example, the largest D50 particle size of the at least two particulate materials is at least 7 times larger than the smallest D50 particle size of the at least two particulate materials. When three or more particulate materials are present in the chocolate composition, the difference between the D50 particle sizes of each of the three or more particulate materials is at least 7 times.

[0052] Preferably, the at least two particulate materials are selected from the group consisting of sugar and cocoa solids. When sugar and cocoa solids are present, the sugar particles and the cocoa solids may have different D50 particle sizes from each other. Alternatively or additionally, the cocoa solids and / or sugar may have a bimodal particle size distribution. In one non-limiting example, the first particulate material is raw sugar and the second particulate material is fine cocoa solids or a mixture of fine and coarse cocoa solids. In an alternative non-limiting example, the first particulate material is coarse cocoa solids and the second particulate material is refined sugar or a mixture of refined sugar and raw sugar. In another non-limiting example, the first particulate material is coarse cocoa solids (D50 approx. 10 μm) contained in the cocoa liquor and the second particulate material is fine cocoa solids (D50 approx. 1-2 μm) contained in the cocoa liquor. In an alternative non-limiting example, the first particulate material is coarse cocoa powder (D50 approximately 10 μm) and the second particulate material is fine cocoa solids (D50 approximately 1-2 μm) contained in the cocoa liquor. In another non-limiting example, the first particulate material is coarse cocoa solids (D50 approximately 10 μm) contained in the cocoa liquor and the second particulate material is raw sugar (D50 approximately 50 μm). In another non-limiting example, the first particulate material is coarse cocoa powder (D50 approximately 10 μm) and the second particulate material is raw sugar (D50 approximately 50 μm).

[0053] Relationship between maximum packing fraction and viscosity Molten chocolate is a non-dilute suspension in which particles are dispersed in a Newtonian solution of fat and interact hydrodynamically, increasing viscous dissipation. Dissipation increases with solid volume (φ) and diverges as the solid volume approaches the maximum filling factor (φ), as illustrated in Figure 1. max (Also called "maximum packing density", "maximum packing efficiency", or "maximum packing volume").

[0054] "Viscosity" as used herein refers to plastic viscosity, a standard parameter used in the chocolate manufacturing industry. Plastic viscosity is a measure of how easily a material flows once it begins to flow, i.e., how "thin" or "thick" it is while it is flowing.

[0055] The viscosity of the suspension can be described by the Krieger Dougherty model, which is known in the art:

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[0057] As shown in equation (1) and FIG. 1, the increase in maximum packing density (Φ max Φ max1 From Φ max2 In contrast, increasing the maximum packing density allows for an increase in the solid phase volume (i.e., a decrease in fat content) without affecting the viscosity of the chocolate composition. Thus, Applicant has surprisingly found that particle packing density can be manipulated and / or optimized to modulate fat content while controlling the rheological properties of the chocolate, particularly its viscosity.

[0058] Particle Packing Parameters For the present invention, it is desirable to have very close or dense packing of the particulate material in the reduced-fat chocolate composition, ideally approaching the highest geometrically allowable packing. Packing density is an inherent geometric property of the particulate system and is influenced by morphological parameters including particle size distribution and particle shape.

[0059] A particle size distribution that is bimodal (i.e., has two arithmetic modes) or polydisperse (i.e., has three or more arithmetic modes) generally has a higher packing density than one that is monodisperse (i.e., has one arithmetic mode), because particles with varying sizes can fill a given space more efficiently. In simple terms, the space between the coarser particles can be occupied by the finer particles in a bimodal or polydisperse system, reducing the size of the interstitial voids between the particles. In the context of the present invention, the more closely the particles are packed together, the smaller the space that can be filled by fat, thereby allowing for a reduction in the total fat content.

[0060] To optimize particle packing, the particle size distribution of the system must be controlled. Although it may be theoretically possible to experimentally optimize particle packing of a simple composition by mixing different proportions of particles with various particle size distributions using trial and error, this is not practically possible for complex multi-component systems such as chocolate.

[0061] Particle shape can also affect particle packing. For example, spheres do not arrange themselves in the same way as cubes, crushed aggregates, or fibers. Previous studies have shown that particles with regular shapes and flat surfaces arrange themselves locally better than those with irregular shapes. Particles with rounder, smoother shapes also generally have a higher packing density than particles with rough surfaces.

[0062] The method of the present invention involves determining optimal particle packing parameters for particulate ingredients in an initial chocolate composition. The particle packing parameters may include particle size distribution, particle shape, and / or relative amounts of at least two particulate ingredients. This determination involves analyzing the particulate ingredients in the initial chocolate composition system and calculating or predicting optimal particle packing parameters for those particulate ingredients.

[0063] This determination of optimal particle packing parameters can be performed using mathematical modeling. For example, system variables can be manipulated in a theoretical model to ascertain the effect on maximum packing fraction while controlling the viscosity parameter. The optimal particle packing parameters are those that result in the highest maximum packing fraction theoretically possible.

[0064] Unlike models used previously (e.g. in EP 1 061 813), the maximum packing calculation employed by the present invention, CPM described below, takes into account both the particle size distribution and shape of the particles to estimate the packing density, which allows very tight particle packing to be achieved in reduced-fat chocolate products.

[0065] Compressible Filling Model (CPM) Preferably, the mathematical model used is the compressible packing model (CPM) developed by Francois de Larrard and described in Goncalves, EV; Lannes, SCdS Food Sci. Technol. 2010, 30, 845-851 and also in Larrard, F. Concrete Mixture Proportioning: a scientific approach, E&FN SPON: An imprint of Routledge, London and New-York, 1999. ISBN 0 419 23500 0, which is incorporated herein by reference in its entirety. This model estimates the maximum packing ratio taking into account both the particle size distribution and the shape of the particles. The CPM is a semi-empirical model developed to describe the packing density achieved by granular mixtures, i.e. concrete. The main principle of the model is that every size class in the mixture interacts with every other size class in the mixture which affects the overall packing density. The model also assumes that for the same material, the shape of the particles is independent of the size class. The shape factor is calculated by considering the particle size distribution and maximum packing fraction of each material.

[0066] The inventors have unexpectedly found that the CPM, originally developed for concrete-based materials, can be used to predict and optimize the maximum packing of sugar and cocoa particles. The inventors have found that the predicted (by CPM) and measured (by Centrifugation Measurement Method 1 below) maximum packing of different cocoa / sugar mixtures as a function of their composition is equal.

[0067] The Compressible Packing Model (CPM) is in fact an improvement of an older model developed by de Larrard and Storvall in 1986, called the Linear Packing Model (LPM). What makes the CPM a better packing model than the LPM is the fact that it takes into account a packing exponent K that depends on the experimental protocol packing. This exponent corresponds to the energy used to experimentally pack the system and therefore makes it possible to have a predicted packing density that represents a real number measured experimentally. The CPM makes it possible to predict two types of packing: the actual maximum packing and the hypothetical maximum packing. The actual maximum packing corresponds to what is known as random close packing (i.e. the packing of particles under a given amount of compaction energy) and as such is a well-known method for determining the packing density, as described herein.

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[0074] Predicting the hypothetical maximum packing fraction for a given mixture

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[0077] To demonstrate how CPM works, we take the example of a two-component mixture composed of component 1 (coarse particles) and component 2 (fine particles). Components 1 and 2 have particle diameters d1 and d2, respectively. CPM assumes that there is at least one dominant diameter in such a mixture. Hence, two different configurations can be distinguished. In the first configuration, the coarse particle diameter dominates. When one fine particle is inserted into the coarse particle packing, and if the fine particle is small enough to fill the space between the coarse particles, there is a loosening of the coarse particle packing that induces a destructuring of the latter. This unstructuring phenomenon is usually called the "loosening effect" (Figure 6(a)). In the second configuration, where fine particles dominate, when one coarse particle is inserted into the fine particle packing, an increase in the porosity near its surface is observed, leading to another kind of unstructuring phenomenon called the "wall effect" (Figure 6(b)). Both effects depend on the geometric interactions between particles of different sizes and are considered as linear functions of the maximum packing fraction of the dominant component.

[0078] In the following, we elaborate how de Larrard includes the effects described above in the hypothetical maximum packing fraction calculation by investigating the same binary system as before (d1 ≥ d2) where partial interactions occur between the particles. In the de Larrard approach, the hypothetical maximum packing fraction of a binary mixture can be defined as:

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[0081] By definition:

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[0083] When partial interactions exist between particles, the loosening effect occurs when the coarse particles dominate, whereas the wall effect is observed when the fine particles dominate. Therefore, to calculate the hypothetical maximum packing fraction, the loosening and wall effect coefficients (a and 1,2 and b 1,2 ) is taken into consideration.

[0084] The loosening effect is due to the presence of fine particles,

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[0089] The wall effect leads to a reduction in the volume occupied by the fine particles. Again, if the coarse particles are far enough apart from each other, the maximum practical packing ratio is

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[0095] These last inequalities are called by de Larrard the non-violable constraints on components 1 and 2. Therefore, from these previous statements, regardless of which component dominates, we can conclude that

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[0097] Boundary condition for coefficient a 1,2 and b 1,2 teeth,

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[0100] Virtual maximum packing fraction considering particle interactions

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[0102] Now consider the general case of the following ternary mixture where d1 ≥ d2 ≥ d3. Assume that 2 is the dominant component and 1 exerts a wall effect on 2, while 3 exerts a loosening effect on 2. Hence,

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[0104] If we follow the same approach as before, we can conclude that:

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[0107] Due to the linearity of the equations that account for relaxation and wall effects, one can easily generalize the equations that give the hypothetical maximum packing fraction for a polydisperse mixture of n components of different sizes. When i is dominant in the polydisperse mixture, the general equation for the hypothetical packing fraction is:

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[0110] Now consider the actual packing fraction of a binary mixture. As already mentioned, there exists a packing index K that allows to infer the actual maximum packing fraction from the hypothetical maximum packing fraction. In the de Larrard approach, the formula for the packing index K for a binary mixture is:

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[0112] For a polydisperse mixture with a predominant component i, the expression for the packing index K is:

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[0115] To be able to use the CPM in a practical manner, it can be programmed using Microsoft Excel™ as software. The software programming steps should follow the de Larrard approach clearly explained in Goncalves, EV; Lannes, SCdS Food Sci. Technol. 2010, 30, 845-851. The software can then be used to determine the optimal particle packing parameters for the initial chocolate composition.

[0116] Obtaining an optimized particulate material Once the optimal particle packing parameters for an initial chocolate composition have been determined, a manufacturer can then use this information to produce a reduced-fat version of the initial chocolate composition that has the same types of particulate ingredients as the initial chocolate composition, but the properties of the particulate materials have been selected or manipulated such that the particle packing parameters of those particulate materials match as closely as possible to the previously determined optimal particle packing parameters.

[0117] In practice, it may not be possible to achieve absolute optimal particle packing parameters, and therefore particle packing parameters in reduced-fat chocolate compositions are described as "optimized" rather than necessarily "optimum." Optimized should be understood to mean that the particle packing parameters are as close as practical to being optimal, or absolutely optimal.

[0118] In one example, a manufacturer may select particulate materials for a reduced-fat chocolate composition by selecting the best combination of particulate materials from an available set of particulate materials, taking into account their characteristics, such as particle size distribution and particle shape. In another example, a manufacturer may manipulate available particulate materials by modifying their size and / or shape using known methods (e.g., grinding, milling, etc.). In either case, the objective is to obtain particulate materials that match as closely as possible the previously determined optimal particle packing parameters.

[0119] When the particle loading parameters are optimized, the reduced-fat chocolate composition has a maximum loading rate that is greater than the maximum loading rate of the initial chocolate composition and a viscosity that is substantially identical to that of the initial chocolate composition. "Substantially the same" viscosity means that the viscosity of the reduced-fat chocolate composition is the same as that of the initial chocolate composition or differs from that of the initial chocolate composition within acceptable limits (e.g., ±5%), taking into account the intended use of the reduced-fat chocolate composition. In other words, the reduced-fat chocolate composition has a viscosity such that it is suitable for the same use as the initial chocolate composition, and can be used as a lower-fat alternative, replacement, or substitute for the initial chocolate composition.

[0120] In general, it can be verified whether a given chocolate composition is a reduced-fat chocolate composition produced according to the method of the present invention, i.e. whether the particulate material in the given chocolate composition is optimized by the method, since in such case the maximum filling rate of the given chocolate composition will closely fit the mathematical model used in the method. The maximum filling rate of a given actual chocolate composition can be measured using the centrifugation measurement method 1 described herein. Alternatively, if the properties such as particle size distribution and / or shape of the particulate material of a given chocolate composition are known, e.g. from the literature, the maximum filling rate of a given chocolate composition can be mathematically calculated, e.g. by inputting said values ​​into the CPM described above, using software. The latter is demonstrated in Example 3 below.

[0121] Example values ​​for maximum filling rate, viscosity, and yield stress Generally speaking, the lower the maximum loading percentage, the higher the fat content of the chocolate composition. A low maximum loading percentage means that there is a lot of fat in the system, which results in inefficient and expensive production. The present invention allows the production of chocolates with a maximum loading percentage higher than that of the initial chocolate composition.

[0122] Usually, a high fat, fully loaded (high maximum loading rate) system should have low viscosity and be easy to process. If fat content or loading density is reduced, the system will have higher viscosity and become more difficult to process. The applicant has surprisingly found that when selecting ingredients to achieve the calculation of maximum loading rate, fat content can be reduced while maintaining the same viscosity.

[0123] The maximum fill factor of the reduced-fat chocolate composition obtained by the method of the present invention is greater than the maximum fill factor of the initial chocolate composition. Preferably, the maximum fill factor of the reduced-fat chocolate composition obtained by the method of the present invention is at least 1% greater than the maximum fill factor of the initial chocolate composition, or more preferably, at least 3% greater than the maximum fill factor of the initial chocolate composition. In non-limiting examples, the maximum fill factor of the reduced-fat chocolate composition is 0.60, 0.61, 0.62, 0.63, 0.64, 0.65, 0.66, 0.67, 0.68, 0.69, 0.70, 0.71, 0.72, 0.73, 0.74, or 0.75 or greater.

[0124] Due to the correlation between maximum fill rate and viscosity detailed above with reference to Figure 1, and the importance of viscosity for chocolate processing, the desired maximum fill rate of a reduced-fat chocolate composition may depend on the end use of the chocolate composition. For example, the ideal maximum fill rate of a chocolate composition for extrusion applications will be different (e.g., higher) than the maximum fill rate of a chocolate for enrobing applications. For example, the maximum fill rate may be 0.72 or more for extrusion applications, 0.63 or more for molding applications, 0.64 or more for enrobing applications, or 0.66 or more for frozen confectionery applications. The Bingham viscosity value for reduced-fat chocolate compositions is 0.1-10 Pa.s. For example, the viscosity may be 1-9 Pa.s, 2-8 Pa.s, 3-7 Pa.s, or 4-6 Pa.s at 40°C.

[0125] Viscosity can be measured with the Bingham plasticity model, a two-parameter rheological model that is widely used to describe the rheological properties of many types of fluids. It can be mathematically described as follows:

[0126]

number

[0127]

number

[0128] Plastic viscosity is a parameter of the Bingham plasticity model. It is the slope of the shear stress / shear rate line above the yield stress.

[0129] The yield stress is the minimum stress that must be overcome to begin to flow from rest. The Bingham yield stress of the reduced-fat chocolate composition of the present invention is from 1 to 150 Pa at 40° C. For example, the yield stress is from 20 to 130 Pa, or from 40 to 110 Pa, or from 60 to 90 Pa.

[0130] Measurement methods for viscosity and yield stress are provided in Measurement Method 2 below.

[0131] The chocolate composition of the present invention has a solid phase volume x and a Bingham plastic viscosity value y of 40° C. or more in Pa.s, x is 0.4 to 0.7; y<264x 3 -330x 2 +141x-20.

[0132] As used herein, "solid phase volume" refers to the ratio of the total volume occupied by the particulate ingredients to the total volume of the melted chocolate composition, which is then the sum of the products of the solid phase (i.e. the particulate ingredients) and the fat phase.

[0133] Manufacturing method In one example, the method of the present invention involves selecting, i.e., actively selecting, at least two particulate materials from among available particulate materials having optimized particle packing parameters as described above. Thus, the selection of particulate materials is driven by mathematical modeling to optimize particle packing density as described above. It is important that the at least two particulate materials selected have different average particle sizes to enhance packing density.

[0134] Because the purpose of the method is to produce a reduced-fat version of the initial chocolate composition, the ingredients (i.e., particulate ingredients, fats, and emulsifiers) selected for use in the reduced-fat chocolate composition will be the same types of ingredients as those used in the initial chocolate composition, except that the particle loading parameters of the particulate ingredients will be different (optimized). For example, if the initial chocolate composition includes cocoa solids, sugar, cocoa fat, and PGPR, the reduced-fat chocolate composition will also contain cocoa solids, sugar, cocoa fat, and PGPR, but the difference is that the cocoa solids and sugar are specifically selected such that the particle loading parameters are optimized.

[0135] In another example, the method of the present invention involves manipulating one or more available particulate materials, for example by changing their particle size distribution and / or particle shape, so as to possess optimized particle packing parameters, as described above. Non-limiting examples of techniques suitable for carrying out this manipulation include grinding or milling.

[0136] Once the at least two particulate ingredients have been obtained, either by selection or manipulation, or both, they are combined with a fat phase and an emulsifier to form a chocolate composition using any known chocolate making technique.

[0137] The fat and emulsifier may be combined with the particulate material separately or simultaneously. In one example, the emulsifier is added to the particulate material / fat mixture. In an alternative example, the emulsifier is added to the fat phase before combining with the particulate material. The fat may be added all at once or in batches.

[0138] The combining preferably occurs during mixing.

[0139] Optionally, the particulate ingredients may be pre-mixed before combining with the fat phase and the emulsifier.

[0140] Optionally, the particulate material may be subjected to a purification process, which may occur at any stage of the method.

[0141] The process may also include a conching step.

[0142] food The chocolate composition of the present invention may form all or part of a food product. The food product is preferably a confectionery product. The confectionery product is a food product that is predominantly sweet in flavor. Exemplary confectionery products include, but are not limited to, chocolate, chocolate-like materials, fat continuous filled materials, frozen confectionery (e.g. ice cream), chocolate pieces within frozen confectionery, baked goods such as biscuits, cakes, breads, and pastries, sweets, candies, gummies, sugar confectionery, tablets, sweets, toffees, boiled sweets, bonbons, candy floss, caramel, fudge, liquorice, marshmallow, nougat, truffles, fondant, ganache. The confectionery product according to the present invention may be a whole food product or may be a part of a food product, such as a filling, binder, shell or coating, inclusion or decoration for a food product. Any combination of the above alternatives is also encompassed by the present invention.

[0143] Preferably, the confectionery product is a chocolate product. In the context of the present invention, the term "chocolate" has the same definition as the term "chocolate composition" (see definition above).

[0144] Measurement method 1. Measuring the maximum filling rate Maximum filling rate of chocolate solids (φ max ) is measured by multi-stage centrifugation in deflocculated conditions (non-agglomerated solids with frictional forces are reduced to a minimum via yield stress optimization) using an emulsifier, PGPR.

[0145] Depending on the recipe (e.g., dark chocolate or milk chocolate), the PGPR dosage requires measurement of yield stress versus PGPR concentration. φ max= φ initial (H initial / H equilibrium ) In the formula, φ initial =V solid / (V solid +V fat ) and V solid is the volume occupied by solid particles in the suspension before centrifugation, and V fat is the volume occupied by fat in the suspension before centrifugation. H initial (also referred to as H0) and H equilebrium is defined below.

[0146] The fat in the liquid state is melted cocoa fat and may contain emulsifiers and, in the case of milk chocolate, fat from whole milk powder.

[0147] The solids content (i.e., particulate material) is as follows: -Dark chocolate: sugar (sucrose), cocoa solids (from cocoa liquor) - for milk chocolate: sugar (sucrose), lactose, cocoa solids (from cocoa liquor), whole milk powder, skimmed milk powder, whey powder. Note that in the composition calculation, the fat of the whole milk powder (typically 26% by weight) is inferred from the amount of compounding material and added to the liquid fat phase.

[0148] [Table 1]

[0149] Device: - Centrifugation: Sorvall Legend XTR Thermo Fisher Scientific (or Sigma3-16PK), measuring temperature is 40°C (the centrifuge is preheated, see below). The rotor is a TX-750 with 4 circular buckets, code 7500 6308.

[0150] The circular bucket houses a holder 7500 3638 that can accommodate seven tubes of 50 mL for a total of 28 tubes. - 50mL polypropylene centrifuge tubes with sealing caps (VWR SuperClear). -RWD 20 Digital IKA agitator with 4 blade propeller 07 410 00. -Metal spatula. -Analytical balance with 0.01g resolution. -Plastic Pasteur pipette. - Caliper from Mitutoyo UK Ltd. (code 500-123U, model n° CD-15B, serial number 287072) powered by a V13GA battery. - A fan-assisted oven set at 50°C for melting and conditioning the chocolate before centrifugation. - A fan assisted oven set at 50°C for melting chocolate without superfines, 60°C for melting milk chocolate with superfines and 80°C for melting dark chocolate with superfines. -Fine marker pen -Calibrated thermocouple (digital readout to 0.1°C)

[0151] material: - Cocoa butter in liquid state used for temperature control (in the oven and during centrifugation). -PGPR (stored at 50°C).

[0152] Chocolate Melting Method: For regular chocolate, melting overnight at 50°C is sufficient.

[0153] For the chocolate with ultrafine particles, the dark chocolate is melted at 80° C. overnight and the milk chocolate is melted at 60° C. overnight.

[0154] After melting, the contents are thoroughly mixed with a RWD 20 Digital IKA stirrer with a 4-blade propeller set at 840 rpm for 5 minutes to ensure that all particles are randomly and homogenously dispersed.

[0155] From φ0 based on the adjacent composition (see definition of φ0 in the next section) and the target φ0, liquid fat needs to be added or removed taking into account the PGPR dosage (PGPR is considered as fat).

[0156] Prepare melted chocolate on a mass scale sufficient for three 50 mL centrifuge tubes (fill level approximately 45 mL) to ensure sufficient sample for Phi max, rheology, and PSD.

[0157] Chocolate composition and φ0: The target φ is at least 0.53 for both dark and milk chocolate, as it has been found that this value does not cause the system to separate into layers of different particle size.

[0158] The optimal PGPR dosage is determined using a flow curve (at 40° C.). Different percentages of PGPR are added to the sample and the viscosity and yield stress are measured to obtain the flow curve. The percentage of PGPR added ranges from 0 to 2.5% (in increments of 0.5%) per total mass of solid particles. The percentage of PGPR with the lowest yield stress is the dosage used to peptize the sample to determine the maximum filling percentage. Without wishing to be bound by theory, the minimum yield stress is used because it corresponds to the yield stress at which the sample is peptized, meaning that there is no interaction between the particles. At the minimum yield stress, the sample can be considered fully peptized and in order to measure the maximum filling percentage the system must be in a peptized state. Exemplary PGPR flow curves for dark chocolate and milk chocolate, respectively, are shown in FIG. 4 and FIG. 5.

[0159] The optimal PGPR dosage, which resulted in the lowest yield stress, was found to be 1.5% of the total solids in dark chocolate and 2.0% of the total solids in milk chocolate.

[0160] Depending on the chocolate composition, the initial φ may be higher or lower than the target φ; in other words, fat may need to be added or removed.

[0161] When fat needs to be removed, the sample is centrifuged at 4500 rpm for about 1 hour. The fat is removed, and the added PGPR and contents are thoroughly mixed using a mixer and then cooled to φ max This gives a fluid smooth slurry which can be directly analyzed for .

[0162] Example 1: Dark Chocolate: Noir 58 HC5738 AA00 * Sugar 40.84w% * Cocoa mass 43.96w% (composed of 54w% fat and 46w% cocoa solids) * Cocoa fat 15.20w%

[0163] [Table 2]

[0164] [Table 3]

[0165] Per 100 g of initial total mass, the total fat removed is 5.15 g (38.94-33.79), which includes PGPR for addition, which is 0.92 g (1.5% x 61.06 g solids).

[0166] Thus, 6.07 g of fat is first removed after centrifugation, and then 0.92 g of PGPR is added.

[0167] Example 2: Milk chocolate: Lacte Equilibre HL3435 AA00 * Sugar 41.86w% * Cocoa mass 10.77w% (composed of 54w% fat and 46w% cocoa solids) * Cocoa fat 24.64w% * Whole milk powder 22.73w% (composed of 26w% fat and 74w% skim milk powder)

[0168] [Table 4]

[0169] [Table 5]

[0170] Per 100 g of initial total mass, the total fat removed is 2.22 g (36.37-34.15), which includes PGPR for addition, which is 0.95 g (1.5% x 63.63 g solids).

[0171] Thus, 3.17 g of fat is first removed after centrifugation, and then 0.95 g of PGPR is added.

[0172] After addition of the PGPR, the contents are mixed using a RWD 20 Digital IKA stirrer with a 4-blade propeller set at 840 rpm for 5 minutes. The deflocculated chocolate is then ready for centrifugation.

[0173] Centrifugation Procedure: 1) Centrifuge tube filling To fill the tube in a vertical position, i.e. without tilting that would occur if the holder diameter was too large and the tube holder height was too low, the empty tube is placed in a tube holder whose diameter is slightly larger than the test tube.

[0174] Transfer the PGPR-deflocculated chocolate to the 45 mL mark, close the tube with a screw cap and, using a fine marker pen, draw four lines on the bottom and top. The four lines are at the intersection of the two diagonals.

[0175] The procedure is performed in three different tubes for an average of three replicates.

[0176] 2) Centrifugal separation preheating and start-up The centrifuge is temperature controlled before the first centrifugation step. The preheating takes about 20 minutes and rotates at 4153 rpm, generating a flow of hot air. The preheating is therefore performed without tubes.

[0177] The centrifuge has two modes for selecting speed / RCF: Operation mode is rotation speed rpm.

[0178] The selection parameters are: -Acceleration 1 (low) -Braking speed 1 (low) -Temperature 40℃

[0179] [Table 6]

[0180] At the end of centrifugation step 5, the initial height (H0) and the height of the dividing line between the solids and fat after the centrifugation process (H equilibrium ) is recorded. The initial height is the total height of the mixture placed in the tube (including both the solid and fat phases). However, the mixture may initially contain air bubbles that will skew the results. Therefore, the total height measurement is taken after centrifugation so that the air bubbles can be removed by centrifugation and the actual total height can be measured.

[0181] Steps 6 and 7 are to ensure that both heights are consistent.

[0182] If not, go for an additional time step until it becomes constant.

[0183] result: The maximum filling rate is: φmax = φ0 [H0 / H equilibrium ]

[0184] Three determinations (three separate 50 mL centrifuge tubes) are averaged and values ​​are reported to two decimal places.

[0185] 2. To measure rheological properties (plastic viscosity and yield stress) Device: A C-VOR Bohlin Rheometer with a thermostatically controlled water bath at -40° C. A vane geometry is used for the measurements. The vane tool diameter is 25 mm, its height is 40 mm, the outer cup diameter is 50 mm and its depth is 60 mm. -Turbo-Test Rayneri VMI Mixer -600mL glass beaker (VWR Collection). -Metal spatula. -Analytical balance with 0.01g resolution. - A fan-assisted oven set at 50 °C for chocolate melting and conditioning prior to sample preparation. - A fan assisted oven set at 50°C for heating the sunflower oil, 60°C for melting the milk chocolate with super fines and 80°C for melting the dark chocolate with super fines.

[0186] material: -Chocolate sample (provided by CARGILL)

[0187] Chocolate Melting: For regular chocolate, melting overnight at 50°C is sufficient.

[0188] For the chocolate with ultrafine particles, the dark chocolate is melted at 80° C. overnight and the milk chocolate is melted at 60° C. overnight.

[0189] Sample preparation: Upon removal from the oven the chocolate samples are mixed with a metal spatula.

[0190] Pour 150 g into a glass beaker. 150 g is the amount needed to fill the vane geometry.

[0191] It is then mixed for 5 minutes at 840 rpm using a turbo test Rayneri VMI mixer. Mixing should be done in a water bath to have the sample at 40° C. after 5 minutes.

[0192] Rheological measurements should be taken immediately after mixing.

[0193] The samples investigated were as follows: Sample 1: Mouscron dark chocolate, Noir 58 HC5738 AA00 * Sugar 40.84w% *Cocoa mass 43.96w% (composed of 54w% fat and 46w% cocoa particles) * Cocoa fat 15.20w% Sample 2: Mouscron milk chocolate, Lacte Equilibre HL3435 AA00 * Sugar 41.86w% * Cocoa mass 10.77w% (composed of 54w% fat and 46w% cocoa particles) * Cocoa fat 24.64w% * Whole milk powder 22.73w% (composed of 26w% fat and 74w% skim milk powder)

[0194] Measurement steps: The rheometer cup was filled with the sample and the measurement sequence was started.

[0195] The sample was 177s -1 The mixture is presheared at a speed of 100 rpm for 300 seconds.

[0196] At the point where 3 seconds remain, the sample is -1 ~1s -1 The sample was subjected to a decreasing shear rate ramp of 1000 s for 500 s, then -1 ~100s -1 The mixture is subjected to an increasing shear rate ramp of 1000 s for 500 s.

[0197] A linear acquisition is chosen to cover the range of shear rates investigated.

[0198] The sequence of decreasing then increasing ramps makes it possible to verify the reproducibility of the measurements, the stability of the samples, and to ensure that the influence of the thixotropy of the investigated systems on the rheological behavior is negligible in this protocol.

[0199] In what follows, only the decay curves will be investigated for data analysis.

[0200] result: The flow curve is fitted with the Bingham equation.

[0201] The analysis procedure is as follows. - Plot the apparent viscosity as a function of shear rate. -100s -1 ~1s -1 Only for the decay curves, which represent shear rates of 100-150%, the shear stress is plotted as a function of shear rate. -Add a linear trendline to the curve so that it has a linear equation of y=ax+b.

[0202] The plastic viscosity and yield stress of the sample are given by a and b, respectively.

[0203] 3. Measuring particle size distribution The particle size distribution of the solid particles of the chocolate is measured by laser diffraction (in the peptized state).

[0204] PGPR is used to disperse the particles in a solvent (i.e., oil). The PGPR dosage required to disperse the particles was determined after several measurements at different dosages (see section PGPR Dosage).

[0205] Definitions of terms: The calculation of the particle size distribution is based on the Mie theory. -d 10 , d 50 , and d 90 is the characteristic diameter obtained from these calculations. -d 10 is the volume-based diameter below which 10% of the particles fall. -d 50 is the volume-based diameter below which 50% of the particles fall. -d 90 is the volume-based diameter below which 90% of the particles fall.

[0206] Calculation of particle size distribution by Mie theory requires the optical indices (refractive index and absorption), which are represented by the real and imaginary parts of the complex refractive index of the material and are defined as follows: N=n-ik where n is the real part and depends on the nature of the material. The imaginary part k represents the absorption of the light beam by the intersecting particles. It also depends on the nature of the material, but also on its purity.

[0207] The solid particles are as follows: - Dark chocolate contains sugar (sucrose), cocoa particles (from cocoa mass) -For milk chocolate: sugar (sucrose), lactose, cocoa particles (from cocoa mass), whole milk powder, skimmed milk powder, whey powder.

[0208] Sunflower oil is used as a solvent.

[0209] [Table 7] 1 The sample is pre-sheared to bring it into a reference conformation. 2 The temperature remains at 40° C. throughout the measurement.

[0210] Device: - Laser diffractometer Mastersizer 3000 equipped with a dispersion unit Hydro LV (Malvern Instruments Ltd., Malvern Panalytical, France). -Turbo-Test Rayneri VMI Mixer -25mL glass bottle with pressure cap (VWR Collection). -Metal spatula. -Analytical balance with 0.01g resolution. -Plastic Pasteur pipette. - A fan-assisted oven set at 50 °C for chocolate melting and conditioning prior to sample preparation. - A fan assisted oven set at 50°C for heating the sunflower oil, 60°C for melting the milk chocolate with super fines and 80°C for melting the dark chocolate with super fines.

[0211] material: -Commercial sunflower oil (AUCHAN, France) - Emulsifier: PGPR (provided by CARGILL). -Chocolate sample (provided by CARGILL)

[0212] Chocolate Melting: For regular chocolate, melting overnight at 50°C is sufficient.

[0213] For the chocolate with ultrafine particles, the dark chocolate is melted at 80° C. overnight and the milk chocolate is melted at 60° C. overnight.

[0214] Sample preparation: 10 g of melted chocolate is added to a solution containing 7 g of sunflower oil and 1 g of PGPR.

[0215] The suspension is mixed at 840 rpm for 5 minutes using a Turbo-Test Rayneri VMI mixer to ensure that all particles are homogenously dispersed.

[0216] The suspension is placed in an oven or water bath at 50° C. overnight.

[0217] For each measurement, 600 ml of sunflower oil is placed at 50° C. overnight.

[0218] The samples investigated were as follows: Sample 1: Mouscron dark chocolate, Noir 58 HC5738 AA00 * Sugar 40.84w% *Cocoa mass 43.96w% (composed of 54w% fat and 46w% cocoa particles) * Cocoa fat 15.20w% Sample 2: Mouscron milk chocolate, Lacte Equilibre HL3435 AA00 * Sugar 41.86w% * Cocoa mass 10.77w% (composed of 54w% fat and 46w% cocoa particles) * Cocoa fat 24.64w% * Whole milk powder 22.73w% (composed of 26w% fat and 74w% skim milk powder)

[0219] Measurement steps: Enter the parameters required for the measurement (name of sample, optical indices of particles and solvent, particle shape...). Set the software to ensure that each measurement is repeated five times.

[0220] The unit cell is filled with 600 ml of preheated sunflower oil and the cell is covered.

[0221] Pour the prepared sample into the cell to an opacity of 12-15%.

[0222] The particle size distribution is measured.

[0223] For a dark chocolate sample, two measurements have to be made: one using the sugar optical index and one using the cocoa index. A particle size distribution by volume is therefore obtained for each measurement.

[0224] For the milk chocolate sample, the principle is the same, but three measurements must be made instead of two. The third measurement is made of the optical index of the milk.

[0225] result: Sample 1: Mouscron dark chocolate, Noir 58 HC5738 AA00 1. Average the particle size distribution by volume obtained from five consecutive measurements using the cocoa optical indices. 2. Average the particle size distribution by volume obtained from five consecutive measurements using the sugar optical index. 3. Estimate the volume percentage of cocoa and sugar particles in the sample.

[0226] Volume percentage of sugar (α):

[0227]

number

[0228] Volume fraction of cocoa particles (β):

[0229]

number

[0230]

number

[0231] For sample 1 we find the following:

[0232]

number

[0233] For sample 1 at a fixed size, Volume fraction of dark chocolate (γ): γ=(α×mean particle size distribution by volume obtained using the optical indices of cocoa)+(β×mean particle size distribution by volume obtained using the optical indices of sugar)

[0234] Sample 2: Mouscron milk chocolate, Lacte Equilibre HL3435 AA00 The analytical procedure is the same as that previously described. In this case, however, milk particles should also be taken into account. Therefore, their volume fraction needs to be determined.

[0235] Volume percentage of sugar (α):

[0236]

number

[0237] Volume fraction of cocoa particles (β):

[0238]

number

[0239] Volume fraction of milk particles (Φ):

[0240]

number

[0241]

number

[0242] For sample 2 we find the following:

[0243]

number

[0244] At a fixed size, Volume fraction of milk chocolate (δ): δ=(α×mean particle size distribution by volume obtained using the optical indices of cocoa)+(β×mean particle size distribution by volume obtained using the optical indices of sugar)+(δ×mean particle size distribution by volume obtained using the optical indices of milk)

[0245] Exemplary embodiments The following are exemplary embodiments of the present invention.

[0246] Exemplary embodiment 1. A reduced-fat chocolate composition comprising: a continuous fatty phase, said fatty phase comprising a fat and optionally an emulsifier; and at least two particulate ingredients distributed throughout the fatty phase; The chocolate composition has a solid volume x and a Bingham plastic viscosity value y of 40° C. or greater in Pa.s, x is 0.4 to 0.7; y<264x 3 -330x 2 A reduced-fat chocolate composition having a fat content of +141x-20.

[0247] Exemplary embodiment 2. A method of preparing a reduced-fat chocolate composition, optionally as described in exemplary embodiment 1, comprising: providing an initial chocolate composition comprising at least two particulate ingredients dispersed throughout a fat phase and an emulsifier; Determining the maximum fill rate and viscosity of an initial chocolate composition; preparing a reduced-fat version of the initial chocolate composition, the preparing comprising: determining optimized particle packing parameters for the at least two particulate ingredients, the optimized particle packing parameters being optimized such that the reduced-fat chocolate composition has a maximum packing rate that is greater than a maximum packing rate of the initial chocolate composition and a viscosity that is substantially the same as a viscosity of the initial chocolate composition; selecting at least two particulate materials having optimized particle packing parameters; combining the selected particulate ingredients with a fat phase and an emulsifier to provide a reduced-fat version of the initial chocolate composition.

[0248] Exemplary embodiment 3. The method of exemplary embodiment 2, wherein the particle packing parameters include particle size distribution, particle shape, and / or relative amounts of at least two particulate materials.

[0249] Exemplary embodiment 4. The method of exemplary embodiment 2 or 3, wherein the optimized particle filling parameters are optimized such that the reduced-fat chocolate composition has a maximum filling rate that is at least 1% greater than the maximum filling rate of the initial chocolate composition.

[0250] Exemplary embodiment 5. The maximum packing fraction is determined using software that predicts the maximum packing fraction based on input values ​​of the particle size distribution and / or shape of the particulate material, or the maximum packing fraction (φ max 5. The method according to any one of exemplary embodiments 2 to 4, wherein the measurement is experimentally determined by measurement method 1.

[0251] Exemplary embodiment 6. A reduced-fat chocolate composition obtained or obtainable by the method according to any one of exemplary embodiments 2-5.

[0252] Exemplary embodiment 7. A reduced-fat chocolate composition according to exemplary embodiment 1 or 6, comprising at least two particulate ingredients dispersed throughout a continuous fatty phase, and an emulsifier; The reduced-fat chocolate composition according to exemplary embodiment 1 or 6, wherein at least two particulate ingredients have different D50 particle sizes from each other.

[0253] Exemplary embodiment 8. A reduced-fat chocolate composition according to exemplary embodiment 7, wherein the D50 particle sizes of the at least two particulate ingredients differ from each other by a factor of 3 to 12.

[0254] Exemplary Embodiment 9. The reduced-fat chocolate composition of any one of Exemplary Embodiments 1 or 6-8, having a Bingham viscosity value of 0.1-10 Pa.s, and a Bingham yield stress of 1-150 Pa at 40°C.

[0255] Exemplary embodiment 10. The reduced-fat chocolate composition of any one of exemplary embodiments 1, or 6-18, wherein the total fat content of the reduced-fat chocolate composition is up to 20% less than the total fat content of the initial chocolate composition.

[0256] Exemplary Embodiment 11. The reduced-fat chocolate composition of exemplary embodiment 10, wherein the total fat content is 31-33% for molding applications, 25-27% for extrusion applications, 37-40% for enrobing applications, or 44-46% for ice cream dipping applications.

[0257] Exemplary Embodiment 12. The method or reduced-fat chocolate composition of any one of Exemplary Embodiments 1-11, wherein the at least two particulate ingredients are selected from the group consisting of sugar, cocoa solids, milk solids, bulking agents, calcium carbonate, nutritional particles, and flavorings, and / or mixtures of two or more thereof.

[0258] Exemplary Embodiment 13. The method or reduced-fat chocolate composition according to any one of Exemplary Embodiments 1-12, wherein the fat phase comprises cocoa fat, a cocoa fat equivalent, a cocoa fat replacer, anhydrous milk fat, fractions thereof, and / or mixtures of two or more thereof.

[0259] Exemplary Embodiment 14. The method or reduced-fat chocolate composition according to any one of exemplary embodiments 1-13, wherein the emulsifier is selected from the group consisting of lecithin, soy lecithin, polyglycerol polyricinoleate (PGPR), ammonium phosphatide (AMP), sorbitan tristearate, sucrose polyerucate, sucrose polystearate, diacetyl tartaric acid mono-di-glyceride phosphate / monoglyceride.

[0260] Exemplary embodiment 15. A food product comprising the reduced-fat chocolate composition of any one of exemplary embodiments 1 or 6-14.

[0261] Working Example Example 1 - Preparation of sweet fat 1. A mixture of 11.7 kg (78%) crystallized sugar (by weight) and 3.3 kg (22%) liquid cocoa butter is thoroughly mixed using a Stephan mixer. 2. The mixture is passed through a triple roll refiner. 3. The captured flakes are collected. 4. These flakes are sent through the same triple roll refiner a second time. 5. 0.15 kg (1%) of cocoa butter is added to the double ground flakes. 6. This mixture is transferred to a Colette conche (vertical shaft). 7. It is conched at 60°C for 5 hours.

[0262] The D50 particle size of sugar in sweet fat is 10.86 μm.

[0263] Example 2 - Determination of chocolate formulations with higher maximum fill factor Commercial dark chocolates for enrobing, moulding, ice cream and extrusion applications were analysed for particle size distribution (PSD) and flow behaviour. The PSD was found to be similar for all applications and the flow behaviour was dependent on the amount of cocoa butter.

[0264] To make comparative testing easier, a commercial chocolate composition was reproduced using sweet fat (prepared according to Example 1) and coarse cocoa particles with a D50 particle size of 9.20 μm to obtain a chocolate with the same composition and the same PSD as the commercial chocolate (formulation 1 in Tables 8 to 12).

[0265] A formulation was then prepared with the same weight composition as the reproduced commercial chocolate, but in which 50% of the coarse cocoa particles were replaced with fine cocoa particles with a D50 particle size of 2.60 μm (formulation 2 in Tables 8 to 12).A formulation was also prepared with the same weight composition as the reproduced commercial chocolate, but in which 100% of the coarse cocoa particles were replaced with fine cocoa particles (formulation 3 in Tables 8 to 12).

[0266] [Table 8] Formulation 1 has a φ of 0.56. Formulation 3 has a φ of 0.58.

[0267] [Table 9] Formulation 1 has a φ of 0.63. Formulation 3 has a φ of 0.65.

[0268] [Table 10] Formulation 1 has a φ of 0.49. Formulation 3 has a φ of 0.51.

[0269] [Table 11] Formulation 1 has a φ of 0.43. Formulation 3 has a φ of 0.44.

[0270] Viscosity and yield stress were measured according to the methods described above and plotted against fat content, and the results are shown in Table 12.

[0271] [Table 12]

[0272] The maximum loading of the formulations was calculated according to Measurement Method 1 above. Figures 2 and 3 show the correlation between the morphology and rheology of the formulations.

[0273] The results show that the maximum loading of formulations 2 and 3 is greater than that of comparable commercial chocolate compositions, but the viscosity and yield stress of formulations 2 and 3 are very similar to those of comparable commercial chocolate formulations, with reduced fat content. Therefore, the present invention allows the production of low-fat, low-calorie chocolate that behaves rheologically like higher fat chocolate. This advantage is consistent across a range of chocolate applications.

[0274] Figure 10 shows the % fat reduction for Formula 2 compared to Formula 1. Figure 11 further shows the % fat reduction for Formula 3.

[0275] Example 3 - Comparison with reduced fat chocolate described in EP 1061813 EP 1 061 813 discloses a "reduced-fat chocolate" in Example 5. The purpose of this investigation was to analyse the chocolate to determine whether it corresponded to the reduced-fat chocolate composition described herein.

[0276] The particle size distribution of the particulate material described in Example 5 of EP 1061813 was determined by reference to Figure 2a of that document.

[0277] The density of skim milk powder was not measured. However, in the literature the density quoted is 1.13 kg / m3 (Walstra P, JTM Wouters and TJ Geurts 2006 Dairy Technology 2, incorporated herein by reference). ndSee the relevant edition CRC / Taylor & Francis.

[0278] The proportions (by weight) of particulate materials disclosed in Example 5 of EP 1 061 813 are as follows: Sugar 68.5% Skim milk powder 25.4% Cocoa powder 6.1%

[0279] The above values ​​were entered into a Microsoft Excel™ spreadsheet programmed to follow the de Larrard procedure (CPM), as described above and in Gocalves, EV; Lannes, SCdS Food Sci. Technol. 2010, 30, 845-851. This outputs a maximum fill value of 0.54, which is low compared to the maximum fill values ​​described herein (0.60 or higher). Without wishing to be bound by theory, it is believed that this is because the particle sizes of the cocoa powder and skimmed milk powder are very similar in EP 1 061 813.

[0280] The proportion of particulate material described in EP 1061813 was then varied to observe the effect on the maximum loading value. The results are shown in Table 13 (CP Mars Varying the ratio had little effect on the maximum fill factor values.

[0281] For comparison purposes, the same ratios were then investigated, but the cocoa powder was replaced with a model for a theoretical cocoa powder with a finer particle size of 1.8 μm. These results are also shown in Table 13 (CP 1.8μm ). Consistent substitution of cocoa powder resulted in higher maximum fill factor values.

[0282] [Table 13] * SMP = skimmed milk powder **CP=cocoa powder

[0283] Example 4 - Effect of particle shape on maximum packing fraction calculated from compressible packing model A typical cocoa powder with the particle size distribution shown in FIG. 8 (measured by granulometry) and a maximum packing fraction of 0.49 (measured by centrifugation) was investigated.

[0284] From the particle size distribution and the maximum packing fraction of a powder, the compressible packing model (CPM) allows the calculation of the specific shape factor β of the powder (here equal to 0.42, as shown in Figure 2). The shape factor β corresponds to the maximum packing fraction of a monodisperse powder with the same particle shape. When dealing with polydisperse powders, the model assumes that for the same powder, the shape of the particles is independent for the size classes.

[0285] To investigate the effect of shape factor on the maximum packing fraction of cocoa, we vary the shape factor and calculate the corresponding maximum packing fraction from the CPM while maintaining the particle size distribution from Figure 8.

[0286] Figure 9a shows the maximum packing factor as a function of shape factor for cocoa powders with a constant particle size distribution calculated from the CPM. It was noted that an increase in the shape factor leads to an increase in the maximum packing factor of the powder. A shape factor equal to 0.64 corresponds to a sphere.

[0287] In the literature, it has been shown that particle aspect ratio is one of the main parameters that affect the maximum particle packing fraction. The aspect ratios of these powders were calculated from a semi-empirical equation developed by Ahmadah et al. (Oumayma Ahmadah, Controle de la rheologie des liants a faibles impacts environnementaux, Universite Gustave Eiffel, These 2021) and the maximum packing fraction was plotted as a function of the aspect ratio (see Figure 9b). It was noted that decreasing the particle aspect ratio while keeping the particle size distribution constant leads to an increase in the maximum packing fraction.

[0288] Increasing the maximum powder loading as described herein allows a reduction in the cocoa fat content in the chocolate composition while keeping the viscosity constant. For example, for the reference cocoa liquor composed of cocoa particles investigated here and containing 54% by total mass (i.e. solid phase volume equal to 0.39) of cocoa fat, an increase in the shape factor from 0.42 to 0.59 (i.e. a decrease in the aspect ratio from 1.8 to 1.2) leads to a reduction in the cocoa fat content from 54% to 41%.

[0289] These results show that the method of the present invention utilizing CPM takes into account particle shape, and that the impact of particle shape on filling properties and therefore chocolate composition ingredient selection is very important.

[0290] Example 5 - Validation Study Samples of typical dark chocolate for different applications manufactured by Cargill Inc., as well as commercially available chocolate samples, were analyzed to test the effectiveness of the CPMs described herein.

[0291] [Table 14]

[0292] [Table 15]

[0293] Commercially available dark chocolate was purchased from the supermarket: Jacques, 365 Essential (Delhaize private label), and Delicata.

[0294] [Table 16]

[0295] [Table 17]

[0296] As can be seen from Figure 12, both the Cargill Inc. sample and the commercial sample fit the master Krieger-Dougherty equation curve of predicted performance. These results indicate that the CPM described herein can be used to predict chocolate performance.

[0297] The features disclosed in the foregoing specification, or the following claims, or the accompanying drawings, and which are represented by specific forms or means for performing a disclosed function, or methods or processes for achieving a disclosed result, may be used in various forms to realize the invention, as appropriate.

[0298] Although specific exemplary embodiments of the present invention have been described, the appended claims are not intended to be limited to only these embodiments, and the claims should be construed literally, operatively, and / or to encompass equivalents.

Claims

1. 1. A reduced-fat chocolate composition comprising: a continuous fat phase, said fat phase comprising a fat and an emulsifier; and at least two particulate ingredients distributed throughout said fat phase; A reduced-fat chocolate composition, wherein the at least two particulate ingredients have different D50 particle sizes from each other, the difference being between 6 and 8 times.

2. It has a solid phase volume x and a Bingham plastic viscosity value y of 40° C. or more Pa.s, x is 0.4 to 0.7; y < 264x ３ -330x ２ The reduced-fat chocolate composition of claim 1 wherein the fat content is +141x-20.

3. 3. A reduced-fat chocolate composition according to claim 1 or 2, having a Bingham plastic viscosity value of 0.1 to 10 Pa.s and a Bingham yield stress of 1 to 150 Pa at 40°C.

4. 4. A fat-reduced chocolate composition according to any one of claims 1 to 3, having a total fat content of 31-33% for moulding applications, 25-27% for extrusion applications, 37-40% for enrobing applications or 44-46% for ice cream dipping applications.

5. A food product comprising the reduced-fat chocolate composition of any one of claims 1 to 4.

6. 1. A method for preparing a reduced-fat chocolate composition, the method comprising: (a) a continuous fat phase, said fat phase comprising a fat and an emulsifier; and providing an initial chocolate composition comprising at least two particulate ingredients distributed throughout said fat phase; (b) optionally measuring the maximum fill rate and viscosity of the initial chocolate composition; (c) preparing a reduced-fat version of said initial chocolate composition, said preparing comprising: i. determining optimized particle packing parameters for the at least two particulate ingredients of the initial chocolate composition, the optimized particle packing parameters being optimized such that the reduced-fat chocolate composition has a maximum packing value that is greater than a maximum packing value of the initial chocolate composition and a viscosity that is substantially the same as the viscosity of the initial chocolate composition; ii. selecting at least two particulate ingredients for the reduced-fat chocolate composition that are identical to the at least two particulate ingredients of the initial chocolate composition but having the optimized particle packing parameters; iii. combining selected particulate ingredients with a fat phase and emulsifiers that are identical to the fat phase and emulsifiers of said initial chocolate composition to provide a reduced-fat version of said initial chocolate composition.

7. The method of claim 6 , wherein the particle packing parameters include particle size distribution, particle shape, and / or relative amounts of the at least two particulate materials.

8. 8. The method of claim 6 or 7, wherein the optimized particle filling parameters are optimized such that the reduced-fat chocolate composition has a maximum filling rate that is at least 1% greater than the maximum filling rate of the initial chocolate composition.

9. The method of any one of claims 6 to 8, wherein the optimized particle packing parameters are determined using mathematical modeling.

10. The method of claim 9 , wherein the mathematical model used is the compressible packing model described herein.

11. A reduced-fat chocolate composition obtained or obtainable by the method according to any one of claims 6 to 10.

12. 12. The method or reduced-fat chocolate composition of any one of claims 1 to 11, wherein the at least two particulate ingredients are selected from the group consisting of sugar, cocoa solids, milk solids, bulking agents, calcium carbonate, nutritional particles, and flavorings, and / or mixtures of two or more thereof.

13. 13. The method or reduced-fat chocolate composition according to any one of the preceding claims, wherein the fat in the fat phase comprises cocoa fat, a cocoa fat equivalent, a cocoa fat replacer, anhydrous milk fat, fractions thereof, and / or mixtures of two or more thereof.

14. 14. The method or reduced-fat chocolate composition according to any one of claims 1 to 13, wherein the emulsifier is selected from the group consisting of lecithin, soy lecithin, polyglycerol polyricinoleate (PGPR), ammonium phosphatide (AMP), sorbitan tristearate, sucrose polyerucate, sucrose polystearate, diacetyl tartaric acid mono-di-glyceride phosphate / monoglyceride.

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