Method for manufacturing multilayer confectionery product

Abstract

FIELD: confectionery production.SUBSTANCE: method for making a multi-layer confectionery product involves preparing a cheesecake mass, placing it between two layers of cookies, heat treating it, and freezing it. Whole butter cookies are used as cookie layers. The cheesecake mixture is placed between layers of cookies before cooking. Then the product is baked in assembled form at a temperature of 90-100 °C for 20-40 minutes. Then it is immediately subjected to shock freezing at a temperature of minus 35 °C - minus 40 °C for 10-20 minutes, providing a temperature difference of at least 130 °C. After which the product is stabilized and stored at a temperature of minus 18 °C.EFFECT: invention is aimed at increasing the structural stability of a multilayer product by reducing moisture migration between layers and preventing the destruction of layers during heat treatment, freezing and subsequent defrosting.5 cl, 2 dwg

Description

[0001] Field of technology to which the invention relates .

[0002] This invention relates to methods for producing a multi-layer confectionery product, including preparing a cheesecake mass, placing it between two layers of cookies, heat treatment and freezing, and can be used in the food industry, in particular in the confectionery and bakery industries - in the preparation of pies and flour confectionery products to expand the range of finished products and improve consumer properties.

[0003] State of the art.

[0004] Methods are known for making multi-layered dessert products such as cheesecake, in which several layers of cream cheese mass are formed on a dough or cookie base, including the inclusion of cookie pieces, after which the product is baked and cooled, followed by refrigeration (see, for example, the recipe for a multi-layered chocolate cheesecake with Oreo cookies at

[0005] https: / / www.russianfood.com / recipes / recipe.php?rid=155250).

[0006] This prior art is closest in technical essence to the claimed invention and is considered a prototype. Therefore, the method proposed in this description will be described in terms of its differences from the prior art.

[0007] The disadvantage of this method is that:

[0008] - either dough or cookies are used as carrier layers, but do not ensure the formation of a product in the form of a sandwich from two layers of whole butter cookies with cheesecake mass placed between them before heat treatment;

[0009] - heat treatment is carried out at elevated temperatures, and subsequent cooling and freezing are carried out without immediate shock freezing with a controlled high temperature difference;

[0010] - there is no regulated stage for stabilizing the product at storage temperature.

[0011] This leads to increased moisture migration between layers, destruction of the product structure and deterioration of the cookie texture during freezing and subsequent defrosting.

[0012] Disclosure of invention.

[0013] The present invention is primarily aimed at providing a method for producing a multi-layer confectionery product, including preparing a cheesecake mass, placing it between two layers of cookies, heat treating and freezing, which allows for increasing the structural stability of the multi-layer product by reducing moisture migration between the layers and preventing the destruction of the layers during heat treatment, freezing and subsequent defrosting, which is the technical problem.

[0014] To achieve this goal, whole butter cookies are used as cookie layers, the cheesecake mass is placed between the cookie layers before heat treatment, after which the product is baked in assembled form at a temperature of 90-100 ° C for 20-40 minutes, then immediately subjected to shock freezing at a temperature of minus 35 ° C to minus 40 ° C for 10-20 minutes, providing a temperature difference of at least 130 ° C, after which the product is stabilized and stored at a temperature of minus 18 ° C.

[0015] Thanks to such advantageous characteristics, it becomes possible to:

[0016] - Ensure high adhesion (bonding) of the layers: baking the product in assembled form at a temperature of 90-100°C allows the cheesecake mass to partially penetrate the porous structure of the whole butter cookie, creating a strong monolithic connection that does not break down during subsequent freezing and defrosting.

[0017] - Maintain the crispy texture of the cookies: using a gentle baking temperature (90-100°C) combined with immediate blast freezing minimizes the transfer of moisture from the cheesecake mixture into the cookies. Blast freezing at -35 to -40°C "locks" the moisture within the plastic layer, converting it into ice microcrystals that do not damage the pore structure of the cookies.

[0018] - Prevent product deformation: a temperature difference of at least 130°C (from +90…+100°C to -35…-40°C) ensures instantaneous fixation of the product's geometric shape. This prevents the cheesecake mixture from spreading under the weight of the top cookie layer and maintains clear layer boundaries.

[0019] - Prevent syneresis (moisture loss): stabilization at -18°C for at least 12 hours allows for the crystallization process to complete and the residual pressure to be evenly distributed within the product. This ensures that after defrosting, the product will not become soggy and the filling will retain its creamy consistency.

[0020] - Improve industrial manufacturability: the use of whole ready-made cookies as outer layers eliminates the need for a complex stage of forming and baking individual base layers, which shortens the production cycle and reduces the percentage of defects during the assembly of a multi-layer product.

[0021] There is another possible variant of this invention, in which the cheesecake mass is formed into a layer, the thickness of which exceeds the thickness of each layer of cookies by 1.5-4 times.

[0022] Thanks to such advantageous characteristics, it becomes possible to:

[0023] - Ensure optimal load distribution: a cheesecake mass-to-cookie thickness ratio of 1.5-4 times creates a structure in which the flexible layer acts as a shock-absorbing layer. At the same time, the two cookie layers act as a rigid frame, preventing deformation of the product under its own weight and mechanical stress (transportation, packaging).

[0024] - Maximize interlayer contact: A cheesecake mixture 1.5-4 times thicker than the cookie ensures sufficient penetration into the porous structure of the cookie during baking, creating a strong mechanical bond. At the same time, the mixture does not become so thick that it compromises the integrity of the cookie or leads to uneven cooking.

[0025] - Maintain organoleptic properties: the specified thickness ratio ensures a harmonious balance between the crispy cookie texture and the creamy cheesecake filling. The cookie layer remains noticeable when biting into the cookie rather than dissolving into the filling, enhancing the product's consumer appeal.

[0026] - Optimize blast freezing speed: a cheesecake layer 1.5-4 times thicker than the cookie layer provides optimal thermal conductivity. During blast freezing at -35 to -40°C, heat is removed from the center of the layer quickly enough (in 10-20 minutes) to prevent the formation of large ice crystals, but slowly enough to avoid thermal stress and microcracks in the structure.

[0027] - Minimize moisture migration: A thick layer of cheesecake mixture (1.5-4 times the thickness of the cookie) creates a sufficient buffer between the two cookie layers, slowing the diffusion of moisture from the center of the cookie to its edges. This is especially important when storing at -18°C, when moisture can migrate from colder to warmer areas, causing the cookie to become soggy.

[0028] - Ensure process reproducibility: the range of 1.5-4 times allows the manufacturer to vary the thickness of the cheesecake mass depending on the type of biscuit used and the desired organoleptic profile, while ensuring that all key technical results (structural stability, texture retention) are achieved."

[0029] There is a possible variant of this invention in which a closed cavity is formed in the cheesecake mass, making up 10-50% of the layer volume, and filled with a fruit filling before baking.

[0030] Thanks to such advantageous characteristics, it becomes possible to:

[0031] - Completely isolate the fruit filling from the cookie layers: forming a closed cavity within the cheesecake mixture creates a hermetic barrier that prevents direct contact between the liquid or semi-liquid fruit filling and the porous structure of the cookie. This prevents capillary absorption of moisture and fruit acids, which could cause the cookie to become soggy and lose its crisp texture, even after defrosting.

[0032] - Preserve the filling's vibrant flavor profile: a closed cavity protects the fruit filling from direct exposure to high baking temperatures (90-100°C). The cheesecake mass surrounding the cavity acts as a heat-insulating layer, preventing the caramelization of sugars and the destruction of volatile aromatic compounds in the fruit. This preserves the fresh, natural flavor of the filling.

[0033] - Prevent filling leakage during baking and freezing: a cavity volume of 10-50% of the cheesecake layer's volume ensures sufficient thickness of the surrounding cheesecake layer (at least 2 mm from the cavity boundary to the outer cookie layers). This ensures that the cheesecake shell maintains its integrity and does not rupture during the thermal expansion of the filling during baking and subsequent contraction during flash freezing.

[0034] - Ensure even moisture distribution: The fruit filling, enclosed in a closed cavity, doesn't come into contact with the cookie, but it does create a zone of increased moisture within the product. The cheesecake mixture surrounding the cavity absorbs some of this moisture, remaining pliable and creamy, while the cookie remains dry and crisp. This creates a contrasting texture.

[0035] - Enhance organoleptic appeal: the hidden fruit filling inside the product creates a "surprise" when biting into it, heightening consumer interest. Furthermore, the filling is not visible from the outside, preserving the product's aesthetic appearance and simplifying packaging.

[0036] - Optimize the component ratio: a range of 10-50% of the cavity volume allows for varying the amount of fruit filling depending on its viscosity and moisture content. For thinner fillings (jams, preserves), use a smaller cavity volume (10-20%), while for thicker fillings (fruit purees, marmalades), use a larger cavity volume (30-50%), while always maintaining sufficient thickness of the cheesecake shell for a seal.

[0037] - Ensures stability during defrosting: a closed cavity prevents moisture from the fruit filling from migrating into the cookies during slow defrosting at room temperature. The cheesecake mixture acts as a buffer layer, gradually thawing while maintaining its structure and preventing moisture from the filling from reaching the cookies for at least 7 days after defrosting.

[0038] There is another possible variant of this invention, in which before placing the cheesecake mass, the cookie layers are pre-cooled to a temperature of 0…+5°C.

[0039] Thanks to such advantageous characteristics, it becomes possible to:

[0040] - Minimize capillary moisture absorption during contact: Pre-cooling cookies to 0 to 5°C slows molecular movement within the cookie's porous structure. When warm cheesecake mixture is applied to cold cookies (after baking), the temperature difference creates a local gradient, but the cold cookie surface prevents rapid absorption of moisture from the mixture into the cookie's pores. This is critical during the first few seconds of contact, when moisture migration is most active.

[0041] - Ensure optimal adhesion without sogginess: Chilled cookies have a denser pore structure. When in contact with the cheesecake mixture, the mixture partially penetrates the pores (necessary for mechanical adhesion of the layers), but without excessive moisture absorption, which would lead to sogginess. This achieves a balance between bond strength and texture preservation.

[0042] - Reduce the rate of moisture evaporation from the cheesecake mixture: A cool cookie surface slows the evaporation of moisture from the cheesecake mixture applied to it. This allows the mixture to spread more evenly across the cookie surface and better fill in microscopic imperfections, creating a more secure bond between the layers.

[0043] - Prevent localized cookie softening: When warm cheesecake mixture is applied to room-temperature cookies, localized heating of the cookie surface can cause softening and loss of firmness. Chilled cookies (0 to +5°C) remain firm even when in contact with the warm mixture, maintaining their geometric shape and not deforming under the weight of the top layer.

[0044] - Optimize baking time: When pre-chilled cookies are placed in the oven, it takes less time to heat the assembled cookies to the target temperature (90-100°C). This means the cheesecake mixture reaches the desired doneness faster, without the cookies having time to overheat and lose their crispiness.

[0045] - Improve process reproducibility: Pre-cooling cookies to a precisely defined temperature (0…+5°C) makes the assembly process more controllable and independent of the ambient temperature in the workshop. This is especially important in industrial production, where conditions may vary, but the result must be consistent.

[0046] - Ensures long-lasting crispiness: By minimizing moisture absorption during assembly, the cookies retain their original moisture content and pore structure. This allows the cookies to remain crispy for at least 7 days after defrosting, as moisture was not absorbed into their structure during assembly.

[0047] - Reduce the percentage of defects during assembly: cold cookies are less susceptible to deformation and brittleness during handling. This reduces the number of damaged cookies that must be rejected before assembling a multi-layer product, increasing the yield of finished products.

[0048] Finally, there is another possible variant of the present invention, in which the stabilization is carried out for at least 12 hours.

[0049] Thanks to such advantageous characteristics, it becomes possible

[0050] - Complete the crystallization of moisture and fats: prolonged storage (at least 12 hours) at -18°C ensures the uniform transition of all free moisture into a microcrystalline state. This prevents the growth of large ice crystals, which could destroy the delicate structure of the cheesecake and lead to condensation during subsequent defrosting.

[0051] - Balance internal stresses within the product: After an extreme temperature change of 130°C (shock freezing), thermal stresses arise within the multilayer structure. Stabilization for 12 hours helps relieve these stresses, preventing cracking of the cookie layers or separation of the cheesecake mixture from the base during storage.

[0052] - Achieve equilibrium moisture distribution: After 12 hours, the moisture within the plastic layer is finally distributed. The moisture is "bound" by the cheesecake components (proteins and fats), making it less mobile. This factor is crucial to prevent moisture from migrating into the cookies after defrosting, allowing them to remain crispy for up to 7 days.

[0053] - Form a dense protective structure at the interface between the layers: long-term stabilization helps strengthen the contact zone between the cookie and cheesecake. This creates a "dry barrier" that provides additional protection against the cookie becoming soggy during chilled distribution.

[0054] - Ensure the stability of the geometric shape: after 12 hours of curing, the product acquires its final rigidity, which allows it to be subjected to automated packaging and long-distance transportation without the risk of deformation or displacement of layers relative to each other.

[0055] - Guarantee the stability of organoleptic properties: long-term stabilization allows the flavor and aroma components of the cheesecake and cookies to “mature” into a single composition, which ensures the high quality of the product immediately after defrosting.

[0056] Brief description of the drawings.

[0057] Other distinctive features and advantages of the present invention will be clearly apparent from the description given below for illustration and not as limiting, with reference to the accompanying drawings, in which:

[0058] - Figure 1 depicts a general view of the product in section,

[0059] - Figure 2 depicts a flow chart of the process according to the invention.

[0060] Figure 1 indicates:

[0061] 1 - top layer of cookies (hard layer),

[0062] 2 - bottom layer of cookies (hard layer),

[0063] 3 - middle layer of cheesecake (plastic layer),

[0064] 4 - adhesion zone (contact boundary where the mass has flowed into the pores of the cookie),

[0065] 5 - closed cavity (inside layer 3),

[0066] 6 - fruit filling (inside cavity 5).

[0067] Implementation of the invention.

[0068] The method for producing a multilayer confectionery product is as follows. We present a comprehensive example of the invention. It should be noted that this example does not limit the application of the invention. Referring to Figure 2:

[0069] Step 1. Preparing the cheesecake mixture

[0070] At this stage, prepare the cheesecake mixture from the following ingredients (per 100 g of finished mixture):

[0071] Cream cheese m.d.f. in dry matter 65% - 45-55 g;

[0072] Sugar - 15-20 g;

[0073] Egg products - 10-15 g;

[0074] Drinking cream m.f. 10% - 8-12 g;

[0075] Dry whey - 2-4 g;

[0076] Maltodextrin - 1-3 g;

[0077] Corn starch - 0.5-1.5 g;

[0078] Acidity regulator (citric acid) - 0.2-0.5 g;

[0079] Drinking water - up to 100 g.

[0080] Mix the ingredients in a mixer at 18-22°C for 5-10 minutes until a homogeneous, plastic mass is obtained. Stabilizer (locust bean gum) is added at a rate of 0.3-0.7 g per 100 g of mass to ensure optimal viscosity and prevent syneresis during freezing.

[0081] Step 2. Pre-cooling the cookie layers

[0082] Whole butter cookies are cooled to a temperature of 0…+5°C in a refrigeration chamber for 30-60 minutes before assembly. This is necessary to minimize the capillary absorption of moisture from the cheesecake mixture into the porous structure of the cookies during contact (as specified in the pre-cooling claim).

[0083] Stage 3. Forming a closed cavity and assembling the product

[0084] A layer of cheesecake mass with a thickness of 8-20 mm (which is 1.5-4 times the thickness of the cookie of 3-6 mm, as specified in the claim) is applied onto the cooled bottom layer of cookies.

[0085] A closed cavity with a volume of 10-50% of the layer volume (as specified in the formula) is formed inside the applied layer, which is filled with fruit filling (jam, confiture, fruit puree) in an amount of 10-50% of the amount of cheesecake mass.

[0086] The distance from the cavity boundary to the outer layers of the biscuit is at least 2mm, which provides a sealed barrier and prevents the fruit filling from coming into contact with the biscuit.

[0087] Place the top layer of cooled cookies on the formed layer, pressing lightly to ensure contact.

[0088] Stage 4. Heat treatment (baking)

[0089] The assembled product is placed in the oven and baked at a temperature of 90-100°C for 20-40 minutes.

[0090] At this stage, the following occurs:

[0091] - Partial penetration of the cheesecake mass into the porous structure of the cookie, creating a strong mechanical adhesion of the layers;

[0092] - Heat treatment of cheesecake mass, ensuring its structuring and stabilization;

[0093] - Protecting the fruit filling (located in a closed cavity) from direct exposure to high temperatures thanks to the surrounding cheesecake layer.

[0094] Stage 5. Shock freezing

[0095] Immediately after baking (within 5-10 minutes), the product is subjected to shock freezing at a temperature of minus 35… minus 40°C for 10-20 minutes, providing a temperature difference of at least 130°C (from +90…+100°C to -35…-40°C).

[0096] At this stage, the following occurs:

[0097] - Instant fixation of the geometric shape of the product;

[0098] - “Locking” moisture inside the plastic layer in the form of ice microcrystals, preventing its migration into the cookies;

[0099] - Prevents the formation of large ice crystals that could ruin the structure of cheesecake and cookies.

[0100] Stage 6. Stabilization

[0101] After shock freezing, the product is transferred to a storage chamber and stabilized at a temperature of minus 18°C ​​for at least 12 hours.

[0102] At this stage, the following occurs:

[0103] - Completion of the crystallization processes of moisture and fats;

[0104] - Alignment of internal thermal stresses arising from extreme temperature changes;

[0105] - Achieving an equilibrium distribution of moisture within the plastic layer, in which the moisture is “bound” by the components of the cheesecake and becomes less mobile;

[0106] - Formation of a dense protective structure at the boundary of the layers, which serves as an additional barrier against the cookies getting soggy.

[0107] It is this stage that ensures the technical result - preservation of the crispy texture of the cookies for at least 7 days after defrosting.

[0108] Step 7. Packaging, storage and transportation

[0109] The stabilized product is packed in a sealed package (plastic bag, vacuum packaging or cardboard box with a polyethylene liner) and stored at a temperature of minus 18°C.

[0110] Shelf life: frozen - 18 months; after defrosting at room temperature (18-22°C) - 7 days.

[0111] Example of a specific implementation:

[0112] For a product weighing 100g:

[0113] - Bottom layer of cookies: 15g (thickness 5mm);

[0114] - Cheesecake mass: 60g (thickness 12mm, which corresponds to a ratio of 2.4:1);

[0115] - Fruit filling (in a closed cavity): 15 g (30% of the layer volume);

[0116] -Top layer of cookies: 15g (thickness 5mm).

[0117] The ratio of cheesecake mass to cookies is 2:1, which is in the range of 1.5-4.0.

[0118] Industrial applicability.

[0119] The method for producing a multilayer confectionery product can be implemented by a specialist in practice and, when implemented, ensures the realization of the stated purpose, which allows us to conclude that the invention meets the “industrial applicability” criterion.

[0120] In order to confirm the effectiveness of this method, a series of tests were conducted, which confirmed an increase in the structural stability of the multilayer product by reducing moisture migration between layers and preventing the destruction of layers during heat treatment, freezing and subsequent defrosting.

Claims

1. A method for producing a multi-layer confectionery product comprising preparing a cheesecake mass, placing it between two layers of cookies, heat treating it and freezing it, wherein the cookie layers are made from whole butter cookies, the cheesecake mass is placed between the cookie layers before heat treating it, after which the product is baked in assembled form at a temperature of 90-100°C for 20-40 minutes, then immediately subjected to shock freezing at a temperature of minus 35°C to minus 40°C for 10-20 minutes, ensuring a temperature difference of at least 130°C, after which the product is stabilized and stored at a temperature of minus 18°C.

2. The method according to paragraph 1, characterized in that the cheesecake mass is formed into a layer, the thickness of which exceeds the thickness of each layer of cookies by 1.5-4 times.

3. The method according to paragraph 1, characterized in that a closed cavity is formed in the cheesecake mass, making up 10-50% of the layer volume, and filled with fruit filling before baking.

4. The method according to paragraph 1, characterized in that before placing the cheesecake mass, the cookie layers are pre-cooled to a temperature of 0…+5°C.

5. The method according to paragraph 1, characterized in that stabilization is carried out for at least 12 hours.

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