Low-fat chocolate

Abstract

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 that have 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.

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 on May 28, 2020, the entire content of which is incorporated herein by reference.

[0002] (Field of the Invention) The present invention relates to a reduced-fat chocolate composition and a method for producing the reduced-fat chocolate composition. In particular, the present invention relates to a reduced-fat chocolate composition that has a substantially same viscosity as equivalent conventionally produced chocolate while having a greater maximum filling rate than the equivalent conventionally produced chocolate, so as to provide a healthier and lower-cost alternative.

BACKGROUND ART

[0003] Consumer preference for "healthier" food products, including chocolate products that contain less fat and / or fewer calories than conventional food products, is increasing. This has created high demand for reduced-fat and reduced-calorie alternatives.

[0004] The fat in chocolate typically comprises or consists of cocoa butter, 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, which can vary significantly depending on the chocolate application. By reducing the amount of cocoa butter 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 chocolate.

[0005] The viscosity of chocolate is important for its intended use. Generally speaking, the less fat a chocolate contains, the thicker and more viscous the melted chocolate becomes. This may be suitable for extrusion applications, but may not be suitable for enrobing or molding applications, for example, because it becomes difficult to process. For example, if the chocolate is too thick, it is mechanically difficult to apply a thin coating of chocolate to confectionery products, 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 commonly added to chocolate to enhance its fluid properties. These emulsifiers help coat the solid particles in the chocolate, allowing them to flow, thereby enabling a partial reduction in fat content, as the emulsifiers perform some of the function of the fat. However, the amount of emulsifiers that can be used is limited. Higher doses of emulsifiers can cause off-flavors and difficulties in processing the chocolate. Some jurisdictions also have legal limits on the amount of emulsifiers that can be used. Some examples of emulsifiers typically used in chocolate are soy, sunflower or rapeseed, ammonium phosphatide, and lecithin produced from polyglycerol polyricinoleic acid (PGPR). Emulsifiers may also be selected, for example, to produce confectionery of special shapes or to reduce the formation of white mold-like spots on chocolate known as chocolate bloom.

[0007] Chocolate is the dispersion of solid particles (e.g., sugar, milk powder, and cocoa solids) in a continuous fat phase. The influence of the particle size distribution of these solid particles on the fluid properties of chocolate has been previously investigated. For example, European Patent No. 1061813 discloses a fluid-modified confectionery having a total fat content of 16-35%, produced by using a specific particle size distribution. The objective of European Patent No. 1061813 was to improve the packing density of the solid particles. However, the particle packing achieved was practically insufficient because the authors were unable to take into account intrinsic characteristics such as particle shape. The maximum packing density of the product described in European Patent No. 1061813, as determined by the method described herein, is only about 0.54 (see Example 3 herein). This means that large spaces still exist between the solid particles filled with expensive cocoa fat. As a result, the chocolate described therein is not cost-effective to produce and has insufficient fluid properties.

[0008] There remains a need for a healthy and low-cost alternative to conventional full-fat chocolate, one that avoids or improves upon the aforementioned drawbacks of reduced-fat chocolate. This invention aims to satisfy this need by increasing the solid phase volume while precisely controlling the fluid behavior of the chocolate by adjusting the morphological parameters of the solid particles in the chocolate, thereby enabling a reduction in fat content. The compositions and methods described herein can be used to produce chocolate compositions suitable for a variety of applications. The compositions of this invention have similar fluid properties to comparable conventional chocolate compositions, while offering advantageous reductions in fat and calories, and lowering manufacturing costs. [Overview of the Initiative]

[0009] In one aspect, the present invention provides a fat-reduced chocolate composition, and the fat-reduced chocolate composition is A continuous fat phase, wherein the fat phase contains fat and an emulsifier, and It comprises at least two particulate materials distributed throughout the entire fat phase, A fat-reduced chocolate composition comprising at least two particulate materials having different D50 particle sizes, wherein the difference is 6 to 8 times.

[0010] The fat-reduced chocolate composition may have a solid phase volume x and a Bingham plastic viscosity value y at Pa·s above 40℃. x is between 0.4 and 0.7. y < 264x 3 -330x 2 It is +141x-20.

[0011] The fat-reduced chocolate composition may have 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.

[0012] The total fat content of the fat-reduced 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 fat-reduced chocolate composition according to the present invention.

[0014] In a further aspect, the present invention provides a method for preparing a low-fat chocolate composition, the method being (a) A continuous fat phase, wherein the fat phase comprises fat and optionally an emulsifier, and To provide an initial chocolate composition comprising at least two particulate materials distributed throughout the fat phase, (b) Optionally, measure the maximum fill density and viscosity of the initial chocolate composition, (c) preparing a fat-reduced version of the initial chocolate composition, and including the preparation of i. Determining optimized particle filling parameters for at least two particulate materials of the initial chocolate composition, wherein the optimized particle filling parameters are determined to be optimized such that the fat-reduced chocolate composition has a maximum filling rate greater than the maximum filling rate of the initial chocolate composition, and a viscosity substantially identical to that of the initial chocolate composition. ii. Selecting at least two particulate materials for the fat-reduced chocolate composition that are identical to at least two particulate materials of the initial chocolate composition but have optimized particle filling parameters, iii. By combining the selected particulate material with a fat phase and emulsifier identical to those of the initial chocolate composition, thereby providing a fat-reduced version of the initial chocolate composition.

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

[0016] The optimized particle filling parameters can be optimized so that the fat-reduced chocolate composition has a maximum filling rate that is at least 1% greater than the maximum filling rate of the initial chocolate composition.

[0017] Optimized particle packing parameters can 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 fat-reduced chocolate composition that can be obtained or obtained by the method of the present invention.

[0019] At least two particulate materials may be selected from the group consisting of sugar, cocoa solids, milk solids, fillers, calcium carbonate, nutritional particles, and flavorings, and / or mixtures of two or more thereof.

[0020] The fat in the fat phase may include or consist of cocoa fat, cocoa fat equivalents, cocoa fat 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, polyerucate sucrose, polystearate sucrose, and mono-di-glyceride / monoglyceride diacetyltartaric acid. [Brief explanation of the drawing]

[0022] [Figure 1] This graph shows the relationship between the viscosity of a typical solution and the volume of the solid phase. [Figure 2] This graph shows the relationship between viscosity and solid phase volume for different chocolate applications: formulation 1 (prior art) and formulations 2 and 3 (according to the present invention) for extrusion, molding, enrobing, and ice cream. [Figure 3] This graph shows the relationship between viscosity and φ / φmax for different chocolate applications: formulation 1 (prior art) and formulations 2 and 3 (according to the present invention) for extrusion, molding, enrobing, and ice cream. [Figure 4] This is the PGPR flow curve for a dark chocolate sample. [Figure 5] This is the PGPR flow curve for a milk chocolate sample. [Figure 6] This represents (a) loosening and (b) wall effects, which are considered in the compressible packing model (CPM). [Figure 7] This graph shows the development of the hypothetical maximum packing density for a two-component mixture. [Figure 8] This graph shows the particle size distribution of a typical cocoa powder with a maximum packing density of 0.49. [Figure 9](a) Shape factor β (b) A series of two graphs (a) and (b) illustrating the maximum packing efficiency as a function of the particle aspect ratio. The particle size distribution is kept constant (shown in Figure 8). [Figure 10] This graph shows the percentage reduction in fat according to the present invention. [Figure 11] This graph shows the percentage reduction in fat according to the present invention. [Figure 12] This graph shows the correlation between viscosity and φ / φmax for known chocolates manufactured by Cargill. [Modes for carrying out the invention]

[0023] Unless otherwise specified, all terms should be given a technical meaning that is consistent with the ordinary meaning in the art, as understood by those skilled in the art.

[0024] All ratios, quantities, and percentages in this specification refer to the total weight of the reduced-fat chocolate composition unless otherwise specified.

[0025] Unless otherwise specified, all parameter ranges include all values ​​at the end of the range and between the ends.

[0026] When used in these specifications and claims, the terms “comprise” and “comprising” and their variations mean that the specified features, processes, or integers are included. The terms should not be construed as excluding the presence of other features, processes, or components.

[0027] Chocolate composition The present invention provides a method for preparing a low-fat chocolate composition. As used herein, the term “chocolate composition” means any composition containing cocoa solids (as defined below) in any amount, even though in some jurisdictions chocolate may be legally defined by the presence of a minimum amount of cocoa solids and / or compounds containing cocoa fat or cocoa fat substitutes. Advantageously, the term “chocolate composition” means any composition that satisfies the legal definition of chocolate in any jurisdiction (preferably the US and / or EU) and also includes any product (and / or its components) in which all or part of the cocoa fat is replaced by cocoa fat equivalents, substitutes, or substitutes. The term “chocolate composition” may also mean a chocolate composition containing cocoa fat and edible solids other than cocoa fat, as well as a “chocolate-like” composition containing a suspension of edible solids in a continuous fat phase other than cocoa fat (e.g., Caramac®). The term “chocolate composition” may mean a whole food product and / or its components. Chocolate may be dark, milk, white, ruby, or crumb chocolate, or variations thereof, as known to those skilled in the art. Chocolate compositions may be suitable for a variety of applications, including but not limited to, extrusion, molding, enrobing, coating, dipping (e.g., for dipped ice cream), spraying, and preparation of chocolate bars, chunks, chips, clamps, vermicelli, and / or sprinkles.

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

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

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

[0031] fat phase The fat phase of a low-fat chocolate composition may contain any fat suitable for chocolate making, including, but is 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 contains one or more emulsifiers. Preferably, the fat phase consists of fats suitable for chocolate making and one or more emulsifiers.

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

[0033] Preferably, the fat phase contains cocoa fat. This cocoa fat in the fat phase is also referred to herein as “added cocoa fat” or “added fat” to distinguish it from cocoa fat that may be inherent in some cocoa solids-containing components, as will be 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 mass relative to the total mass of the chocolate composition. Preferably, it is 5% to 35%, more preferably 10% to 30%, and more preferably 15% to 25%.

[0035] The total fat content of the fat-reduced chocolate composition includes added fat in the fat phase and any fat that may be part of the particulate components (e.g., in whole fat cocoa powder). The total fat content of the fat-reduced chocolate composition according to the present 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 fat-reduced chocolate composition according to the present 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 fat-reduced chocolate composition according to the present invention may be 20% or more of the total weight of the fat-reduced 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 present invention, the total fat content is 26% or less, preferably 25% or less, and more preferably 24% or less.

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

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

[0038] As used herein, the term “sugar” refers to any type of sweetener containing formulations suitable for use in food. Non-limiting examples of sugars that may 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 of these.

[0039] Advantageously, sugar is sucrose. As used herein, the term “sucrose” includes, but is not limited to, various forms of sucrose, including standard (e.g., granulated or crystalline) cooking sugar, powdered sugar, refined sugar, powdered sugar, liquid sugar, silk sugar, raw sugar, sugarcane sugar, and molasses.

[0040] Advantageously, the sugar is a formulation comprising crystalline sugar dispersed in cocoa fat, hereinafter referred to as "sweetening fat," prepared according to Example 1 below. The sweetening fat is essentially cocoa-free chocolate or dairy-free white chocolate.

[0041] In one non-limiting example, the chocolate composition contains any amount of sugar, such as 1% to 65% by weight, for example, 5% to 60% by weight, or 10% to 55% by weight, or 15% to 50% by weight, or 20% to 45% by weight, or 25% to 40% by weight, or 30% to 35% by weight, relative to the total weight of the chocolate composition. Preferably, the sugar is present in an amount of 40% to 60%, or preferably 45% to 60%, or preferably 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 to describe particle size distribution and is sometimes called the "mean" or "statistical mean" particle size. "D50" refers to the maximum particle size (e.g., the diameter of a typical spherical particle) at which 50% of the volume of particles in a sample have a maximum particle size less than that value. In other words, in the cumulative distribution of the maximum particle size of particles in a sample, 50% of the distribution is less than the D50 value.

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

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

[0045] The sugar used in the present invention may be "raw sugar" having a D50 particle size greater than 50 μm, or it may be "refined sugar" having a D50 particle size of 1 μm to 15 μm, preferably 7 μm to 13 μm, preferably 8 μm to 12 μm, or preferably about 10 μm. In a preferred embodiment, the refined sugar is sugar in the form of 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 above D50 values ​​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 components such as cocoa liquid or cocoa mass. In the case of such cocoa solids-containing components, the term cocoa solids refers only to solid cocoa particles and not to any surrounding fats that may also be present in the component. Preferably, the cocoa solids are standard cocoa powder (having a fat content of 10-12%), fat-reduced or defatted cocoa powder (e.g., produced using solvent extraction), or cocoa liquid.

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

[0048] The cocoa solids may be "coarse cocoa solids" having a D50 particle size of 5 μm to 15 μm, preferably 7 μm to 13 μm, 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, preferably 1 to 3 μm, or about 2 μm. In some examples, the cocoa solids may have a bimodal particle size distribution. In that case, the above D50 values ​​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 the preliminary steps of the claimed method by applying known processes such as grinding, pulverizing, or similar processes for raw sugar or cocoa solids.

[0050] "Bulking agents," also known as "fillers," may be used as particulate materials to influence the sensory or fluid 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 fiber, cereal fiber, and / or other plant fiber. 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, gluco-oligosaccharides, galactooligosaccharides, MOS (mannose oligosaccharides, also known as mannan-oligosaccharides or manno-oligosaccharides), pectin, psyllium, inulin, and resistant starch.

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

[0052] Preferably, 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 cocoa solids may have different D50 particle sizes. 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 and raw sugar. In another non-limiting example, the first particulate material is coarse cocoa solids (D50 approximately 10 μm) contained in the cocoa liquid and the second particulate material is fine cocoa solids (D50 approximately 1-2 μm) contained in the cocoa liquid. In alternative, non-limiting examples, the first particulate material is coarse cocoa powder (D50 approximately 10 μm), and the second particulate material is fine cocoa solids contained in cocoa liquid (D50 approximately 1-2 μm). In another non-limiting example, the first particulate material is coarse cocoa solids contained in cocoa liquid (D50 approximately 10 μm), and the second particulate material is raw sugar (D50 approximately 50 μm). In yet 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 filling density and viscosity Melted chocolate is an undiluted suspension in which particles are dispersed in a Newtonian solution of fat and interact hydrodynamically, increasing viscous dissipation. Dissipation increases with solid phase volume (φ), as illustrated in Figure 1, and diverges as the solid phase volume approaches the maximum packing density (φ). max (Also known as "maximum packing density," "maximum packing efficiency," or "maximum packing volume.")

[0054] As used herein, "viscosity" 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, that is, how "thin" or "thick" it is while it is flowing.

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

[0056]

number

[0057] As shown in equation (1) and Figure 1, the increase in maximum packing density (Φ max Φ max1 From Φ max2 Increasing the particle packing density (which specifically means moving to a certain point) allows for a decrease in viscosity (illustrated by arrows showing the difference between the solid and dashed lines), while the solid phase volume remains constant. Conversely, increasing the maximum packing density allows for an increase in solid phase volume (i.e., a decrease in fat content) without affecting the viscosity of the chocolate composition. Thus, the applicant has surprisingly found that particle packing density can be manipulated and / or optimized to control the fat content while controlling the fluid properties of the chocolate, particularly its viscosity.

[0058] Particle packing parameters In relation to the present invention, it is desirable that the particulate material in the fat-reduced chocolate composition has a very close or tight packing, and ideally, it is desirable to approach the best geometrically acceptable packing. Packing density is an inherent geometric property of the particle system and is influenced by morphological parameters including particle size distribution and particle shape.

[0059] Particle size distributions that are bimodal (i.e., have two arithmetic modes) or polydispersive (i.e., have three or more arithmetic modes) generally have a higher packing density than monodispersive (i.e., have one arithmetic mode) distributions because particles with varying sizes can more efficiently fill a given space. Simply put, the spaces between coarser particles can be occupied by finer particles in bimodal or polydispersive systems, reducing the size of interstitial voids between particles. In the context of this invention, when particles are packed more tightly together, there is less space that can be filled by fat, thereby allowing for a reduction in total fat content.

[0060] To optimize particle packing, the particle size distribution of the system must be controlled. While it may theoretically be possible to experimentally optimize the particle packing of simple compositions by mixing different proportions of particles with various particle size distributions using trial and error, this is not practically feasible 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 higher packing densities than particles with rougher surfaces.

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

[0063] This determination of the optimal particle packing parameters can be carried out using mathematical modeling. For example, system variables can be manipulated in a theoretical model to examine their effect on the maximum packing density while controlling the viscosity parameter. The optimal particle packing parameters are those that result in the maximum possible maximum packing density in theory.

[0064] Unlike models previously used (for example, in European Patent No. 1061813), the maximum fill density calculation employed in the present invention, CPM described below, estimates the fill density by taking into account both the particle size distribution and shape of the particles. This makes it possible to achieve very dense particle filling in low-fat chocolate products.

[0065] Compressible Filling Model (CPM) Preferably, the mathematical model used is the compressible packing model (CPM) developed by Francois de Larrard, which is 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 (the whole is incorporated herein by reference). This model estimates the maximum packing density by considering both the particle size distribution and shape of the particles. 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 all size classes in the mixture interact with all other size classes in the mixture that affect the overall packing density. The model also assumes that, for the same material, the particle shape is independent of the size class. The shape factor is calculated by considering the particle size distribution and maximum packing density of each material.

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

[0067] The Compressible Packing Model (CPM) is, in fact, an improvement on an older model called the Linear Packing Model (LPM), developed by de Larrard and Storvall in 1986. 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 allows for having a predicted packing density that represents an experimentally measured real number. The CPM allows for the prediction of two types of packing, namely the actual maximum packing rate and the hypothetical maximum packing rate. The actual maximum packing rate corresponds to what is known as random sealed packing (i.e., packing of particles under a given amount of compaction energy), which itself is described herein.

[0068]

number

[0069]

number

[0070]

number

[0071]

number

[0072]

number

[0073]

number

[0074] Prediction of the hypothetical maximum packing density for a given mixture.

[0075]

number

[0076]

number

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

[0078] In the following, the inventors detail how de Larrard incorporates the effects described above into the calculation of the virtual maximum packing density by investigating the same two-component system as before (d1≧d2) where partial interactions occur between particles. In de Larrard's method, the virtual maximum packing density of a two-component mixture can be defined as follows:

[0079]

number

[0080]

number

[0081] According to the definition:

[0082]

number

[0083] When partial interactions exist between particles, the loosening effect occurs when coarse particles are dominant, while the wall effect is observed when fine particles are dominant. Therefore, in order to calculate the virtual maximum packing density, the loosening and wall effect coefficients (a, respectively) are calculated. 1,2 and b 1,2 ) will be taken into consideration.

[0084] The loosening effect is due to the presence of fine particles, resulting in partial volume

[0085]

number

[0086]

number

[0087]

number

[0088]

number

[0089] The wall effect leads to a reduction in the volume occupied by fine particles. Again, the actual maximum packing rate is achieved when coarse particles are sufficiently far apart from each other.

[0090]

number

[0091] [Mathematical formula] Whatever the dominant diameter is,

[0092] [Mathematical formula] can be calculated. Therefore, in any case, it can be described as follows.

[0093] [Mathematical formula] Then,

[0094] [Mathematical formula]

[0095] These last inequalities are called inviolability constraints for components 1 and 2 by de Larrard. Therefore, from these previous descriptions, it can be concluded as follows regardless of which component is dominant.

[0096] [Mathematical formula]

[0097] The boundary condition a for the coefficient 1,2 and b 1,2 is

[0098] [Mathematical formula] (no interaction between particles), a 1,2 =b 1,2 =0,

[0099] [Mathematical formula] (total interaction between particles), a1,2 =b 1,2 = 1

[0100] Virtual maximum packing density considering particle interactions

[0101]

number

[0102] Here, we consider the general case of the following three-component mixture where d1 ≥ d2 ≥ d3. Assume that 2 is the dominant component, 1 exerts a wall effect on 2, while 3 exerts a loosening effect on 2. Therefore,

[0103]

number

[0104] If we follow the same methodology as before, we can conclude the following:

[0105]

number

[0106]

number

[0107] Due to the linearity of the equations explaining loosening and wall effects, the equations giving the virtual maximum packing efficiency for a polydisperse mixture of n components of different sizes can be easily generalized. When i is dominant in the polydisperse mixture, the general equation for the virtual packing efficiency is as follows:

[0108]

number

[0109]

number

[0110] Here, we consider the actual packing density of the two-component mixture. As already mentioned, there exists a packing index K that allows us to estimate the actual maximum packing density from the hypothetical maximum packing density. In the de Larrard method, the formula for the packing index K for a two-component mixture is as follows:

[0111]

number

[0112] For a polydisperse mixture with the dominant component i, the formula for the packing index K is as follows:

[0113]

number

[0114]

number

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

[0116] To obtain optimized particulate materials. Once the optimal particle-filling parameters for the initial chocolate composition are determined, the manufacturer can then use this information to produce a fat-reduced version of the initial chocolate composition having the same types of particulate components as the initial chocolate composition, but the properties of the particulate materials are selected or manipulated so that the particle-filling parameters of those particulate materials match as closely as possible to the previously determined optimal particle-filling parameters.

[0117] In practice, it is not always possible to achieve absolutely optimal particle-filling parameters, so we will describe particle-filling parameters in fat-reduced chocolate compositions that are "optimized" rather than necessarily "optimal." Optimization should be understood as meaning that the particle-filling parameters are as close as possible to being optimal, or absolutely optimal.

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

[0119] When particle filling parameters are optimized, the reduced-fat chocolate composition has a maximum filling rate greater than that of the original chocolate composition and a viscosity substantially identical to that of the original chocolate composition. “Substantially identical” viscosity means that the viscosity of the reduced-fat chocolate composition is the same as that of the original chocolate composition, or differs from that of the original chocolate composition within an acceptable limit (e.g., ±5%), considering the intended use of the reduced-fat chocolate composition. In other words, the reduced-fat chocolate composition has a viscosity suitable for the same uses as the original chocolate composition and can be used as a lower-fat alternative, replacement, or substitute for the original chocolate composition.

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

[0121] Exemplary values ​​of maximum filling density, viscosity, and yield stress. Generally speaking, the lower the maximum fill density, the higher the fat content of the chocolate composition. A low maximum fill density means that a large amount of fat is present in the system, resulting in inefficient and expensive production. This invention makes it possible to produce chocolate with a maximum fill density higher than that of the initial chocolate composition.

[0122] Typically, a high-fat, well-filled (high maximum fill density) system should have low viscosity and be easy to process. If the fat content or pack density is reduced, the system will have higher viscosity and become more difficult to process. Surprisingly, the applicant has found that when selecting components to achieve the maximum fill density calculation, the fat content can be reduced while maintaining the same viscosity.

[0123] The maximum fill density of the fat-reduced chocolate composition obtained by the method of the present invention is greater than the maximum fill density of the initial chocolate composition. Preferably, the maximum fill density of the fat-reduced chocolate composition obtained by the method of the present invention is at least 1% greater than the maximum fill density of the initial chocolate composition, or more preferably at least 3% greater than the maximum fill density of the initial chocolate composition. In non-limiting examples, the maximum fill density of the fat-reduced 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 higher.

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

[0125] Viscosity can be measured using the Bingham plasticity model. The Bingham plasticity model is a two-parameter fluid dynamics model widely used to describe the fluid dynamics properties of many types of fluids. It can be mathematically explained 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 initiate flow from rest. The Bingham yield stress of the fat-reduced chocolate composition of the present invention is 1 to 150 Pa at 40°C. For example, the yield stress is 20 to 130 Pa, or 40 to 110 Pa, or 60 to 90 Pa.

[0130] The 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 at 40°C or higher in Pa·s. x is between 0.4 and 0.7. y < 264x 3 -330x 2 It is +141x-20.

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

[0133] Manufacturing method In one example, the method of the present invention involves actively selecting, i.e., 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 the particle packing density as described above. It is important that the at least two selected particulate materials have different average particle diameters in order to enhance the packing density.

[0134] Since the objective of the method is to produce a fat-reduced version of the initial chocolate composition, the components selected for use in the fat-reduced chocolate composition (i.e., particulate materials, fats, and emulsifiers) will be of the same type as those used in the initial chocolate composition, except that the particle filling parameters of the particulate materials will be different (optimized). For example, if the initial chocolate composition contains cocoa solids, sugar, cocoa fat, and PGPR, the fat-reduced chocolate composition will also contain cocoa solids, sugar, cocoa fat, and PGPR, the difference being that the cocoa solids and sugar are specifically selected so that the particle filling 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, thereby having optimized particle packing parameters as described above. Non-limiting examples of suitable techniques for carrying out this operation include grinding or crushing.

[0136] Once at least two particulate materials are obtained by either 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] Fats and emulsifiers can be combined with particulate materials 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 being combined with the particulate material. Fats can be added all at once or in batches.

[0138] Combinations preferably occur during mixing.

[0139] Optionally, particulate materials may be pre-mixed before being combined with the fatty phase and emulsifier.

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

[0141] The method 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 primarily sweet in flavor. Exemplary confectionery products include, but are not limited to, chocolate, chocolate-like materials, continuous fat-filling materials, frozen confectionery (e.g., ice cream), chocolate pieces in frozen confectionery, baked goods such as biscuits, cakes, bread, and pastries, sweets, candies, gummies, sugar confectionery, tablets, sweets, toffee, boiled sweets, bonbons, candy floss, caramel, fudge, licorice, marshmallows, nougat, truffles, fondant, and ganache. The confectionery product according to the present invention may be an entire food product, or it may be part of a food product such as a filling, binder, shell or coating, filling or decoration for the food product. Any combination of the above substitutes is also included in the present invention.

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

[0144] Measurement method 1. Measure the maximum filling rate. Maximum filling rate of chocolate solids (φ max ) is measured using the emulsifier PGPR by multi-stage centrifugation in the deflocculated state (where non-aggregated solids with frictional force are reduced to a minimum through yield stress optimization).

[0145] Depending on the recipe (e.g., dark chocolate or milk chocolate), the PGPR dosage requires measurement of the yield strength 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 V is the volume occupied by solid particles in the suspension before centrifugation, and V fat This is the volume occupied by fat in the suspension before centrifugation. H initial (Also referred to as H0) and H equilebrium It is defined as follows:

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

[0147] The solid content (i.e., particulate material) is as follows: -Regarding dark chocolate: Sugar (sucrose), cocoa solids (derived from cocoa liquid) -Regarding milk chocolate, the ingredients are sugar (sucrose), lactose, cocoa solids (derived from cocoa liquid), whole milk powder, skim milk powder, and whey powder. Note that in composition calculations, the fat content of whole milk powder (typically 26% by weight) is estimated from the amount of other ingredients and added to the liquid fat phase.

[0148] [Table 1]

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

[0150] The circular bucket houses holder 7500 3638, which can accommodate seven 50 mL tubes, for a total of 28 tubes. - 50 mL polypropylene centrifuge tube with sealing cap (VWR SuperClear). RWD 20 Digital IKA Agitator with 4-blade propeller 07 410 00. - Metal spatula. A chemical balance with an accuracy of -0.01g. - Plastic Pasteur pipette. - A caliper from Mitutoyo UK Ltd. (code 500-123U, model n°CD-15B, serial number 287072) that operates on a V13GA battery. - A fan-assisted oven set to 50°C for melting and adjusting the chocolate before centrifugal separation. - A fan-assisted oven set to 50°C to melt chocolate without ultrafine powder, set to 60°C to melt milk chocolate with ultrafine powder, and set to 80°C to melt dark chocolate with ultrafine powder. - Fine marker pen - Calibrated thermocouple (digital reading in 0.1°C increments)

[0151] material: - Liquid cocoa fat used for temperature control (in the oven and during centrifugal separation). -PGPR (store at 50°C).

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

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

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

[0155] From the φ0 based on the adjacent composition (see the 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 fat).

[0156] To ensure sufficient sample for Phimax, fluid dynamics, and PSD, prepare melted chocolate on a mass scale sufficient to fill three 50 mL centrifuge tubes (filled to approximately 45 mL).

[0157] Chocolate composition and φ0: The target φ0 is at least 0.53 for both dark chocolate and milk chocolate, as it was found that 0.53 is the value at which the system does not separate into layers of different particle sizes.

[0158] The optimal PGPR dosage is determined using a flow curve (at 40°C). Different proportions of PGPR are added to the sample, and viscosity and yield stress are measured to obtain the flow curve. The proportion of PGPR added ranges from 0 to 2.5% (in 0.5% increments) per total mass of solid particles. The proportion of PGPR at which the yield stress is lowest is the dosage used to dispasticate the sample to determine the maximum packing density. While not wishing to be constrained by theory, the minimum yield stress is used because it corresponds to the yield stress at which the sample dispasticates, meaning there are no interactions between particles. At the minimum yield stress, the sample can be considered completely dispasticated, and the system must be in a dispastic state to measure the maximum packing density. Exemplary PGPR flow curves for dark chocolate and milk chocolate, respectively, are shown in Figures 4 and 5.

[0159] The optimal PGPR dosage that minimizes 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 φ0 may be higher or lower than the target φ0; 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 approximately 1 hour. After the fat is removed, the added PGPR and contents are thoroughly mixed using a mixer, φ max It provides a fluid smooth slurry that can be directly analyzed (without the need for culture).

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

[0163] [Table 2]

[0164] [Table 3]

[0165] In the initial state, per 100g of total mass, the amount of total fat to be removed is 5.15g (38.94-33.79g), which includes 0.92g (1.5% × 61.06g of solids) of added PGPR.

[0166] Therefore, after centrifugation, 6.07 g of fat is removed first, followed by the addition of 0.92 g of PGPR.

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

[0168] [Table 4]

[0169] [Table 5]

[0170] In the initial state, per 100g of total mass, the amount of total fat to be removed is 2.22g (36.37-34.15g), which includes 0.95g (1.5% × 63.63g of solids) of added PGPR.

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

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

[0173] Centrifugation procedure: 1) Centrifuge tube filling To fill the tube, place an empty tube in a tube holder with a diameter slightly larger than the test tube, in a vertical position, i.e., without the tilt that occurs when the holder diameter is too large and the tube holder height is too low.

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

[0175] The procedure is carried out in three different tubes to average the three replicas.

[0176] 2) Centrifugal separation preheating and starting The centrifuge is temperature-controlled before the first centrifugal separation step. Preheating takes about 20 minutes and involves rotating at 4153 rpm to generate a flow of hot air. Therefore, preheating is performed without tubing.

[0177] The centrifuge has two modes for selecting speed / RCF. The operating mode is rotational speed in rpm.

[0178] The selection parameters are as follows: -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 (H of the dividing line between the solid content and the fat after the centrifugation process equilibrium ) are recorded. The initial height is the total height of the mixture placed in the tube (including both the solid phase and the fat phase). However, the mixture may initially contain air bubbles that would distort the results. Therefore, the total height measurement is performed after centrifugation, so that air bubbles can be removed by centrifugation and the actual total height can be measured.

[0181] Steps 6 and 7 are to confirm that both heights are constant.

[0182] If not, proceed with an additional 1-hour step until they become constant.

[0183] Results: The maximum filling rate is as follows. φmax=φ0[H0 / H equilibrium

[0184] Take the average of 3 measurements (3 separate 50 mL centrifuge tubes) and report the value to the second decimal place.

[0185] 2. Measuring rheological properties (plastic viscosity and yield stress) Apparatus: C-VOR Bohlin Rheometer equipped with a water bath thermostatically controlled at -40°C. A vane geometry is used for the measurement. 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 - 600 mL glass beaker (VWR Collection). - Metal spatula. - Analytical balance with 0.01 g precision. ​- A fan-assisted oven set at 50°C for chocolate melting and conditioning before sample preparation. - A fan-assisted oven set at 50°C for sunflower oil heating, set at 60°C for melting milk chocolate with ultrafine powder, and set at 80°C for melting dark chocolate with ultrafine powder.

[0186] Materials: - Chocolate samples (provided by CARGILL)

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

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

[0189] Sample preparation: Mix the chocolate sample with a metal spatula when it is taken out of the oven.

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

[0191] Then, mix it using a Rayneri VMI turbo test mixer at 840 rpm for 5 minutes. The mixing should be carried out in a water bath so that the sample is at 40°C after 5 minutes.

[0192] Rheological measurements must be performed immediately after mixing.

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

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

[0195] The sample is 177s -1 It is pre-sheared for 300 seconds at this speed.

[0196] With 3 seconds remaining, the sample was 100s -1 ~1s -1 It is subjected to a decreasing shear rate gradient for 500 seconds, and then 1 second -1 ~100s -1 It is subjected to a gradient of increasing shear rate for 500 seconds.

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

[0198] The decreasing, then increasing gradient sequence allows for verification of measurement reproducibility, sample stability, and ensures that the thixotropic influence of the investigated system on its fluid behavior is negligible in this protocol.

[0199] In the following sections, we will only examine the decrease curve for data analysis purposes.

[0200] result: The flow curve can be 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 Plot the shear stress as a function of shear rate only for the decreasing curve, which refers to the shear rate of . Add a linear approximation curve to the curve so that it has the 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 the particle size distribution The particle size distribution of solid particles in chocolate is measured by the laser diffraction method (in a deflocculated state).

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

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

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

[0207] The solid particles are as follows: -Regarding dark chocolate, it contains sugar (sucrose) and cocoa particles (derived from cocoa mass). -Regarding milk chocolate: Sugar (sucrose), lactose, cocoa particles (derived from cocoa mass), whole milk powder, skim milk powder, whey powder.

[0208] Sunflower oil is used as a solvent.

[0209] [Table 7] 1 The sample is pre-sheared to bring it to a reference structural state. 2 The temperature remained at 40°C during the measurement.

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

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

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

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

[0214] Sample preparation: Add 10g of melted chocolate to a solution containing 7g of sunflower oil and 1g 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 homogeneously dispersed.

[0216] Leave the suspension in an oven or water bath at 50°C overnight.

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

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

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

[0220] Fill the unit cell with 600 ml of preheated sunflower oil and cover the cell.

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

[0222] Measure the particle size distribution.

[0223] Two measurements must be performed on the dark chocolate sample. The optical index of sugar is used in the first measurement, and the index of cocoa is used in the second. Therefore, the particle size distribution by volume is obtained for each measurement.

[0224] For milk chocolate samples, the principle is the same, but instead of two measurements, three measurements are required. The third measurement is performed using the optical index of the milk.

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

[0226] Volume percentage of sugar (α):

[0227]

number

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

[0229]

number

[0230]

number

[0231] Regarding sample 1, the following is found:

[0232]

number

[0233] Regarding sample 1 in a fixed size, Volume percentage of dark chocolate (γ): γ = (α × average particle size distribution by volume obtained using the optical index of cocoa) + (β × average particle size distribution by volume obtained using the optical index of sugar)

[0234] • Sample 2: Mouscron milk chocolate, Lacte Equilibre HL3435 AA00 The analytical procedure is the same as previously described. However, in this case, milk particles must also be considered. Therefore, it is necessary to determine their volume proportion.

[0235] Volume percentage of sugar (α):

[0236]

number

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

[0238]

number

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

[0240]

number

[0241]

number

[0242] Regarding sample 2, the following is found:

[0243]

number

[0244] In fixed sizes, Volume percentage of milk chocolate (δ): δ = (Average particle size distribution by volume obtained using α × optical index of cocoa) + (Average particle size distribution by volume obtained using β × optical index of sugar) + (Average particle size distribution by volume obtained using δ × optical index of milk)

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

[0246] Exemplary Embodiment 1. A low-fat chocolate composition, A continuous fat phase, wherein the fat phase comprises fat and optionally an emulsifier, and It comprises at least two particulate materials distributed throughout the entire fat phase, The chocolate composition has a solid phase volume x and a Bingham plastic viscosity value y at 40°C or higher Pa·s. x is between 0.4 and 0.7. y < 264x 3 -330x 2 A fat-reduced chocolate composition with a value of +141x-20.

[0247] Exemplary Embodiment 2. A method for optionally preparing the fat-reduced chocolate composition described in Exemplary Embodiment 1, wherein the method is: To provide an initial chocolate composition comprising at least two particulate materials dispersed throughout the fat phase and emulsifier, To determine the maximum filling density and viscosity of the initial chocolate composition, This includes preparing a fat-reduced version of the initial chocolate composition, and preparing The objective is to determine optimized particle-filling parameters for at least two particulate materials, wherein the optimized particle-filling parameters are determined to be optimized such that the fat-reduced chocolate composition has a maximum fill density greater than that of the initial chocolate composition, and a viscosity substantially identical to that of the initial chocolate composition. Selecting at least two particulate materials having optimized particle packing parameters, A method for providing a fat-reduced version of an initial chocolate composition by combining selected particulate materials with a fat phase and an emulsifier.

[0248] Exemplary Embodiment 3. The method according to 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 according to Exemplary Embodiment 2 or 3, wherein the optimized particle filling parameters are optimized such that the fat-reduced chocolate composition has a maximum filling rate at least 1% greater than the maximum filling rate of the initial chocolate composition.

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

[0251] Exemplary Embodiment 6. A fat-reduced chocolate composition obtained or obtainable by the method described in any one of Exemplary Embodiments 2 to 5.

[0252] Exemplary Embodiment 7. A fat-reduced chocolate composition according to Exemplary Embodiment 1 or 6, The mixture comprises at least two particulate materials dispersed throughout the continuous fat phase, and an emulsifier. A fat-reduced chocolate composition according to exemplary embodiment 1 or 6, wherein at least two particulate materials have different D50 particle sizes.

[0253] Exemplary Embodiment 8. The fat-reduced chocolate composition according to Exemplary Embodiment 7, wherein the D50 particle diameters of at least two particulate materials differ from each other by 3 to 12 times.

[0254] A fat-reduced chocolate composition according to any one of the exemplary embodiments 1 or 6-8, having a Bingham viscosity value of 0.1 to 10 Pa.s and a Bingham yield stress of 1 to 150 Pa at 40°C.

[0255] Exemplary Embodiment 10. A fat-reduced chocolate composition according to any one of Exemplary Embodiments 1 or 6-18, wherein the total fat content of the fat-reduced chocolate composition is up to 20% less than the total fat content of the initial chocolate composition.

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

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

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

[0259] Exemplary Embodiment 14. The method according to any one of Exemplary Embodiments 1 to 13 or a reduced-fat chocolate composition, 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, and mono-di-glyceride / monoglyceride diacetyltartaric acid.

[0260] Exemplary Embodiment 15. A food comprising the fat-reduced chocolate composition described in any one of Exemplary Embodiments 1 or 6-14.

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

[0262] The D50 particle size of sugar in sweetening fats is 10.86 μm.

[0263] Example 2 - Determination of a chocolate formulation with a higher maximum fill density Commercial dark chocolates for enrobing, molding, ice cream, and extrusion applications were analyzed for particle size distribution (PSD) and flow behavior. The PSD was similar across all applications, and the flow behavior was found to be dependent on the amount of cocoa fat.

[0264] To facilitate comparative testing, a commercially available chocolate composition was reproduced using sweetening fat (prepared according to Example 1) and coarse cocoa particles with a D50 particle size of 9.20 μm to obtain chocolate with the same composition and PSD as the commercially available chocolate (Formulation 1 in Tables 8-12).

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

[0266] [Table 8] The diameter of compound 1 is 0.56. The diameter of compound 3 is 0.58.

[0267] [Table 9] The φ of compound 1 is 0.63. The diameter of compound 3 is 0.65.

[0268] [Table 10] The diameter of compound 1 is 0.49. The diameter of compound 3 is 0.51.

[0269] [Table 11] The diameter of compound 1 is 0.43. The diameter of compound 3 is 0.44.

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

[0271] [Table 12]

[0272] The maximum filling rate of the mixture was calculated according to measurement method 1 described above. Figures 2 and 3 show the correlation between the morphology of the mixture and its fluid dynamics.

[0273] The results show that while the maximum fill density of formulations 2 and 3 is greater than that of comparable commercially available chocolate compositions, the viscosity and yield strength of formulations 2 and 3 are very similar to those of comparable commercially available chocolate formulations, and the fat content is reduced. Therefore, the present invention enables the production of low-fat, low-calorie chocolate that behaves fluidly like higher-fat chocolate. This advantage is consistent across a wide range of chocolate applications.

[0274] Figure 10 shows the percentage reduction in fat for formulation 2 compared to formulation 1. Figure 11 further shows the percentage reduction in fat for formulation 3.

[0275] Example 3 - Comparison with fat-reduced chocolate described in European Patent No. 1061813 European Patent No. 1061813 discloses a “reduced-fat chocolate” of Example 5. The purpose of this study was to analyze the chocolate to determine whether it corresponds to the reduced-fat chocolate composition described herein.

[0276] The particle size distribution of the particulate material described in Example 5 of European Patent No. 1061813 was determined by referring to Figure 2a of the said document.

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

[0278] The proportions (by weight) of particulate materials disclosed in Example 5 of European Patent No. 1061813 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 method (CPM), which is described above and in Gocalves, EV; Lannes, SCdS Food Sci. Technol. 2010, 30, 845-851. This produced a maximum fill-fill value of 0.54. This value is lower than the maximum fill-fill values ​​(0.60 or higher) described herein. While not bound by theory, this is thought to be because the particle sizes of cocoa powder and skim milk powder are very similar in European Patent No. 1061813.

[0280] Next, the effect on the maximum packing density was observed by changing the ratio of particulate material as described in European Patent No. 1061813. The results are shown in Table 13 (CP Mars Varying the ratio had little effect on the maximum filling rate.

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

[0282] [Table 13] * SMP = Skim milk powder **CP = Cocoa powder

[0283] Example 4 - Effect of particle shape on maximum packing efficiency calculated from compressible packing model We investigated a typical cocoa powder with the particle size distribution shown in Figure 8 (measured by particle size analysis) and a maximum packing density of 0.49 (measured by centrifugation).

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

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

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

[0287] Literature has shown that particle aspect ratio is one of the main parameters influencing the maximum particle packing density. The aspect ratios of these powders were calculated using 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 density was plotted as a function of aspect ratio (see Figure 9b). It was noted that reducing the particle aspect ratio while maintaining a constant particle size distribution leads to an increase in the maximum packing density.

[0288] As described herein, increasing the maximum packing density of the powder allows for a reduction in the cocoa fat content in the chocolate composition while maintaining a constant viscosity. For example, consider a standard cocoa liquid composed of the cocoa particles investigated here, containing 54% cocoa fat by total mass (i.e., a solid phase volume equal to 0.39). 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 demonstrate that the present invention's method utilizing CPM takes particle shape into account, and that the influence of particle shape on filling properties and, therefore, on the selection of chocolate composition components, is extremely important.

[0290] Example 5 - Verification Investigation Typical dark chocolate samples for different uses manufactured by Cargill Inc., as well as commercially available chocolate samples, were analyzed to test the effectiveness of CPM as described herein.

[0291] [Table 14]

[0292] [Table 15]

[0293] I bought some store-bought dark chocolate at 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 Cargill Inc. samples and commercially available samples fit the master Krieger-Dougherty equation curve of the expected performance. These results demonstrate that the CPM described herein can be used to predict the performance of chocolate.

[0297] The features disclosed in the aforementioned specification, or the following claims, or the accompanying drawings, as represented by means for performing a particular function, or the methods or processes for achieving the disclosed results, may be used in various forms to realize the invention, as necessary.

[0298] While specific exemplary embodiments of the present invention have been described, the appended claims are not intended to be limited to these embodiments only. The claims should be interpreted literally as encompassing the purposes and / or equivalents thereof.

Claims

1. A low-fat chocolate composition, A continuous fat phase, wherein the fat phase comprises fat and an emulsifier, and The adipose phase comprises at least two particulate materials distributed throughout the entire adipose phase, The at least two particulate materials have different D50 particle diameters, and their ratio is 6 to 8 times. The fat-reduced chocolate composition has a maximum fill density of 0.6 or more. Here, the at least two particulate materials are selected to achieve the maximum packing density. Here, the maximum packing density is determined by particle packing parameters and a compressible packing model that include both particle size distribution and particle shape. Low-fat chocolate composition.

2. It has a solid phase volume x and a Bingham plastic viscosity value y at Pa.s of 40°C or higher. x is between 0.4 and 0.7, The fat-reduced chocolate composition according to claim 1, wherein y < 264x3 - 330x2 + 141x - 20.

3. The fat-reduced 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. A fat-reduced chocolate composition according to any one of claims 1 to 3, wherein the total fat content is 31 to 33% for molding applications, 25 to 27% for extrusion applications, 37 to 40% for enroving applications, or 44 to 46% for ice cream dipping applications.

5. The fat-reduced chocolate composition according to any one of claims 1 to 4, wherein the at least two particulate materials are selected from the group consisting of sugar, cocoa solids, milk solids, fillers, calcium carbonate, nutritional particles, and flavorings, and / or mixtures of two or more thereof.

6. The fat-reduced chocolate composition according to any one of claims 1 to 5, wherein the fat in the fat phase comprises cocoa fat, cocoa fat equivalent, cocoa fat substitute, anhydrous milk fat, fractions thereof, and / or mixtures of two or more thereof.

7. A food product comprising the fat-reduced chocolate composition according to any one of claims 1 to 6.

Images