Process of recovering frozen confection components

Abstract

A process of recovering ingredients of a frozen confection item, the recovered ingredients being used in the manufacture of a subsequent frozen confection item, wherein the frozen confection item comprises a first phase of frozen aerated confection, and a second phase of solid fat-based confection, the process comprising the steps of a) processing the frozen confection so that the first phase becomes flowable, but wherein the second phase remains solid; followed by b) sieving the processed frozen confection, such that the first phase passes through the sieve and the second phase does not pass through the sieve; followed by c) recovering the first phase and / or the second phase; followed by d) manufacturing a subsequent frozen confection item from ingredients that include at least a portion of the recovered first phase and / or second phase.

Description

[0001] PROCESS OF RECOVERING FROZEN CONFECTION COMPONENTS

[0002] Field of the invention

[0003] The present invention relates to a process of recovering ingredients of a frozen confection item, the recovered ingredients being used in the manufacture of a subsequent frozen confection item.

[0004] Background of the invention

[0005] Frozen confections which consist of ice cream, frozen yoghurt, or the like coated with chocolate, frozen fruit juice, or other coatings are popular products. In the manufacture of such products in a factory environment, there is inevitably a proportion of rejects that fail to pass quality control checks at various stages of manufacture.

[0006] Such rejected products can be simply discarded as waste or recycled (often termed as reworking) into the manufacture of a subsequent frozen confection. If the frozen confection was made from a single homogeneous material, e.g. ice cream or sorbet, such reworking would be a relatively simple matter. However, recycling becomes technically very challenging when the frozen confections includes different phases, e.g. chocolate coated ice cream.

[0007] Such products may also be supported on a stick so that they can be conveniently consumed without being held directly. Chocolate-coated stick products are one example of this type of product that have been known for many years.

[0008] Once manufactured, an uncoated frozen aerated confection can be coated by dipping into a bath of liquid coating to form the coating or they may also be sprayed or enrobed with liquid coating. Once coated, the frozen products are typically blast frozen and a wrapper may be added to enclose the frozen confection. Additionally, the ice cream can include additional confections, such as sauces and candy inclusions, or chocolate pieces or chips. However, errors in manufacturing can result at various stages of manufacture, such as incomplete coatings, incorrect weight, inadequately aligned sticks, or a failure in the wrapping stage.

[0009] DE 2125685 A1 discloses a method of separating the confectionery content, such as fondant or praline from the coating of chocolate. The chocolates are broken up and placed in a cold water tank, at a temperature that dissolves the contents but has no effect on the chocolate. The filling is collected as it settles to the bottom of the tank, from time to time. The chocolate pieces are recovered and reused e.g. as broken chocolate chips.

[0010] EP 1277411 B1 discloses a method and apparatus for preparing a frozen ice confection comprising soft fruit pieces. In a test example, soft fruit pieces are separated from ice cream via washing in a sieve.

[0011] The ability to recycle multi-phase frozen confections when they are rejected would be highly desirable.

[0012] Summary of the invention

[0013] In a first aspect the invention relates to a process of recovering ingredients of a frozen confection item, the recovered ingredients being used in the manufacture of a subsequent frozen confection item, wherein the frozen confection item comprises a first phase of frozen aerated confection, and a second phase of solid fat-based confection, the process comprising the steps of a) processing the frozen confection so that the first phase becomes flowable, but wherein the second phase remains solid; followed by b) sieving the processed frozen confection, such that the first phase passes through the sieve and the second phase does not pass through the sieve; followed by c) recovering the first phase and / or the second phase; followed by d) manufacturing a subsequent frozen confection item from ingredients that include at least a portion of the recovered first phase and / or second phase. Thus, the ingredients forming the first phase and second phase are recovered, and are used for another useful purpose, such as being reworked into a subsequent frozen confection item, reducing the amount of waste generated in the manufacturing process.

[0014] Thus, in a second aspect, the invention relates to a subsequent frozen confection item comprising recovered first phase and / or second phase obtainable by the process as described herein.

[0015] Process of Recovery

[0016] The sieving process acts as a filter to separate out the first phase from the second phase.

[0017] Preferably the sieving or filtering is carried out at a temperature where the first phase is at least partially melted but wherein the second phase remains solid. A suitable range of temperatures is from -4°C to 25°C, preferably from 0°C to 15°C, more preferably from 3 to 10°C.

[0018] The term “does not pass through the sieve” means that at least 95wt%, preferably at least 99wt% of the second phase remains in the sieve.

[0019] The term “passes through the sieve” means that at least 95wt%, preferably at least 99wt% of the first phase passes through the sieve.

[0020] The process involves the separation of the first phase from the second phase, and so mechanical breakage of the first and / or second phase is preferably carried out prior to or during the sieving step, to make separation more effective.

[0021] In general the first phase is water soluble and / or water dispersible, whereas the second phase is not water dispersible and / or water soluble at the temperatures carried out. This difference in behaviour is primary governed by the relative fat contents of the two phases, discussed below. Therefore, preferably water is added during or after the sieving step, to enhance the separation of the two phases. In particular, water is preferably added to facilitate the passage of the first phase through the sieve, in a dispersed and / or soluble form. The sieving step may include vibration. The sieving step may include also include rotation. Vibration and rotation of the sieve may take place separately or at the same time, as desired to optimize the separation. Preferably the sieve has holes having an effective diameter of from 0.5 to 3mm. It has surprisingly been found that suitable devices are those not known for use in the ice cream industry, and may be rotary brush strainers, (e.g available from Spxflow), continuous centrifuges (e.g the Sormac SC available from Sormac V.B., The Netherlands) or batch centrifuges (e.g. the Sormac MC-44 from Sormac V.B., The Netherlands). Notably, such devices are taken from completely unrelated technical fields such as those related to the washing of salad leaves.

[0022] If rotation or centrifugation of the sieve is employed, then the speed of rotation must be such that it does not result in breakage or compaction of the second phase, as this will inhibit filtration. In particular, breakage of the second phase to such a size that they would pass through the holes in the sieve must be avoided. Additionally, if vibration is employed, then care must be taken that thermal energy transmitted to the second phase pieces does not result in their melting.

[0023] Once the majority of the first phase has passed through the sieve, preferably water is added in a rinsing step, following the sieving step, to rinse any first phase that remains adhered to the second phase. Devices known for washing salads have been found to be useful and include the Sormac SW-80, Washing Flume WF, or the PULSTAR (all available from Sormac V.B., The Netherlands).

[0024] It is additionally preferred that a gas stream is directed onto the second phase following the sieving step (and if present, after the rinsing step) to remove any adhered first phase and / or water therefrom. For example, compressed air or nitrogen may be conveniently used. Such a gas stream is typically at a temperature where the second phase remains solid, i.e. no greater than 15°C. Again, devices not used in the ice cream industry have surprisingly been found to be suitable, including the LDT-50 / 5D and the DWB dewatering conveyor (both available from Sormac V.B., The Netherlands). Vacuum techniques may be employed as an alternative.

[0025] Additionally or alternatively, a second sieving or filtering step may be employed to remove any adhered first phase and / or water, e.g. in a centrifuge type of sieve. As a result of the process the first phase will be in a flowable and liquid form. Preferably it is kept in this state to be used in the manufacture of the subsequent frozen confection in liquid form, e.g. during the formation of any ice cream mix prior to freezing.

[0026] First Phase

[0027] In general the majority of the frozen confection item will be made up from the first phase of frozen aerated confection. Preferably the frozen confection item comprises from 50 to 97 wt% of the first phase of frozen aerated confection.

[0028] Frozen confection means a confection made by freezing a pasteurised mix of ingredients such as water, fat, sweetener, protein (normally milk proteins), and optionally other ingredients such as emulsifiers, stabilisers, colours and flavours. Aerated frozen confections include ice cream, frozen yoghurt and the like. In a preferred embodiment the aerated frozen confection is an ice cream.

[0029] Aerated means that the frozen confection composition comprises air. The term "aerated" means that gas has been intentionally incorporated into the composition, for example by mechanical means. The gas can be any gas, but is preferably, particularly in the context of food products, a food-grade gas such as air, nitrogen, nitrous oxide, or carbon dioxide. The extent of aeration is defined in terms of "overrun". The amount of air present is defined as overrun and is defined and calculated as disclosed in: ‘The Science of Ice Cream’, C. Clarke, RSC 2004, chapter 4, where, %overrun is defined in volume terms (measured at atmospheric pressure) as: volume of frozen aerated product - volume of premix at ambient temp UR = - x tut) volume of premix at ambient temp

[0030] The amount of overrun present in the first phase will vary depending on the desired product characteristics. In the context of the present invention the level of overrun is typically from 0 to 200%, preferably from 20 to 150%, more preferably from 30 to 100%.

[0031] Frozen confections may be prepared, for example, according to methods provided in the ‘The Science of Ice Cream’, C. Clarke, RSC 2004, for example: chapters 3, 4 and 8; and ‘Ice Cream’ 5thEd., Marshall and Arbuckle, 1996, Chapman & Hall, New York. N.Y., in particular chapters 11 , 12 and 22.

[0032] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art (e.g. in frozen food manufacture). Definitions and descriptions of various terms and techniques used in frozen confectionery manufacture are found in “Ice Cream”, 7th Edition R.T. Marshall, H.D. Goff and R.W. Hartel, Kluwer Academic / Plenum Publishers, New York 2013.

[0033] The first phase typically becomes flowable at a temperature in the range of from -10 to 10°C, preferably from -5 to 5°C.

[0034] The first phase may comprise fat at a level of from 0 to 25 wt%.

[0035] Second Phase

[0036] The second phase is a solid fat-based confection that is typically not aerated, and not water-soluble at room temperature. In general a minority of the frozen confection item will be made up from the second phase of solid fat-based confection. Preferably the frozen confection item comprises from 3 to 50 wt% of the second phase of solid fat-based confection.

[0037] Preferably the second phase is present as a coating, that may completely surround or partially surround the aerated frozen confection. Suitable fat-based confections include chocolate (dark chocolate, white chocolate, milk chocolate), or a chocolate analogue or couverture. The term “chocolate” is not intended to be limited to compositions that can legally be described as chocolate in any particular country but includes any products having the general character of chocolate. It therefore includes chocolate-like materials which are made using fats other than cocoa butter (for example coconut oil). Chocolate usually contains non-fat cocoa solids, but it is not essential that it does so (e.g. white chocolate). The term chocolate analogue means chocolate-like fat-based confectionery compositions made with fats other than cocoa butter (for example cocoa butter equivalents, coconut oil or other vegetable oils). Such chocolate analogues are sometimes known as couvertures. Chocolate analogues need not conform to standardized definitions of chocolate which are used in many countries. In addition to fat and cocoa solids, chocolate and chocolate analogues may contain milk solids, sugar or other sweeteners and flavourings. A fat-based coating may consist essentially of vegetable oil and sugar, together with colours and I or flavours as required.

[0038] Coatings are typically applied to the frozen confection as liquids, but solidify when they are cooled down, for example as a result of contact with the frozen confection. Chocolates have complex solidification behaviour because they contain mixtures of different triglycerides which can crystallize in different forms. For example, cocoa butter can exist in six different crystalline forms (polymorphs). As chocolate solidifies, triglycerides begin to crystallize. Within a few seconds the chocolate becomes dry to the touch and has plastic or leathery texture. Crystallization continues slowly, so that it typically takes several hours or days for the triglycerides to fully crystallize and so that the chocolate reaches its maximum brittleness. Chocolate made from fats other than cocoa butter displays similar behaviour, but typically crystallizes over a narrower temperature range and reaches maximum brittleness more quickly. Preferably the coating is chocolate.

[0039] The thickness of any coating can vary according to the particular design of frozen confectionery. However coating thicknesses of from 0.5 to 3mm are preferred, more preferably from 1mm to 2mm. Inclusions such as chocolate pieces may vary in size from a few mm up to 2cm in length.

[0040] The second phase typically has a melting temperature in the range of from 10 to 50°C, preferably from 15 to 40°C.

[0041] The second phase may comprise fat at a level of from 30 to 85 wt%.

[0042] Fats

[0043] Fats are largely made up of triglycerides (approximately 98%), together with minor amounts of other components such as phospholipids and diglycerides. Triglycerides are esters of glycerol with three fatty acids. Fatty acids which have no carbon-carbon double bonds are said to be saturated (SAFA), whereas fatty acids that contain one carboncarbon double bond is said to be mono-unsaturated (MLIFA) and multiple carbon-carbon double bonds are referred to as polyunsaturated (PLIFA). Fats that are liquid at room temperature are often referred to as ‘oils’, but are considered to be fats for the purpose of the present invention. SAFA, MLIFA and PLIFA contents of fats and oils are given in “The Lipid Handbook”, Third Edition, Frank D Gunstone, John L Harwood and Albert Dijkstra, CRC Press 2007.

[0044] Fats may be obtained from any suitable food-grade source. Fats may have a dairy or a non-dairy origin.

[0045] Sugars

[0046] The present invention preferably utilises a frozen confection having at most 20 wt% of total sugars. As used herein the term “sugars” refers exclusively to digestible mono- and di-saccharides. The total sugar content of a frozen confection is thus the sum of all of the digestible mono- and di-saccharides present within the frozen confection, including any lactose from milk solids and any sugars from fruits. In preferred embodiments the frozen confection has at most 17.5 wt%, more preferably at most 15 wt%, more preferably still at most 12.5 wt%, yet more preferably at most 10 wt%, even more preferably at most 7.5 wt%, more preferably at most 6wt% total sugars. Preferably the frozen confection contains at least 1 wt%, more preferably at least 2 wt%, more preferably still at least 5 wt% total sugars.

[0047] Stabilisers

[0048] The frozen confection further typically contains stabilisers, the primary purposes of which is to produce smoothness in body and texture, retard or reduce ice and lactose crystal growth during storage, and to provide uniformity of product and resistance to melting. Additionally, they stabilize the mix to prevent wheying off, produce a stable foam with easy cut-off in the freezer, and slow down moisture migration from the product to the package or the air. The action of stabilisers in ice cream results from their ability to form gel-like structures in water and to hold free water. Iciness can be controlled by stabilizers due to a reduction in the growth of ice crystals over time, related to a reduction in water mobility as water is entrapped by their entangled network structures in the serum phase. Suitable stabilisers include one or more of tara gum, guar gum, locust been gum, carrageenan, gelatin, alginate, carboxymethyl cellulose, xanthan and pectin. The frozen confection contains at least 0.45 wt%, preferably at least 0.5 wt%, more preferably at least 0.55 wt%, more preferably still at least 0.6 wt%, even more preferably at least 0.75 wt%, yet more preferably at least 1.0 wt%, still more preferably at least 2.0 wt%, most preferably at least 5.0 wt% of stabilisers. Preferably the frozen confection contains at most 20 wt%, more preferably at most 15 wt%, more preferably still at most 12.5 wt%, even more preferably at most 10 wt%, most preferably at most 7.5 wt% of stabilisers.

[0049] The frozen confection also may contain non-saccharide sweetener which as defined herein consist of: The intense sweeteners aspartame, saccharin, acesulfame K, alitame, thaumatin, cyclamate, glycyrrhizin, stevioside, neohesperidine, sucralose, monellin and neotame; and The sugar alcohols HSH (hydrogenated starch hydrosylate - also known as polyglycitol), eythritol, arabitol, glycerol, xylitol, sorbitol, mannitol, lactitol, maltitol, isomalt, and palatinit. The frozen confection preferably contains at least 0.01 wt% of a non-saccharide sweetener, preferably at least 0.02 wt%, more preferably at least 0.03 wt%, more preferably still at least 0.04 wt%, yet more preferably at least 0.05 wt%, yet more preferably still at least 0.10 wt%, even more preferably at least 0.15 wt%, yet more preferably at least 0.20 wt%, more preferably at least 0.25 wt%, most preferably at least 0.50 wt% of a non-saccharide sweetener. Preferably the frozen confection contains at most 2.5 wt%, more preferably at most 2 wt%, more preferably still at most 1 wt% of a non-saccharide sweetener.

[0050] Examples

[0051] Coated ice cream confections were manufactured, with the following formulation

[0052] First Phase of frozen aerated confection

[0053] This formulation is a typical ice cream formulation with a fat content of 8%.

[0054] The second Phase of solid fat-based confection is a typical chocolate couverture formulation with a fat content of 44 wt% with a melting point in the range of from 32 to 37°C.

[0055] The first phase was prepared in a typical ice manufacturing process, and aerated to an overrun of approximately 100% to form the first phase of frozen aerated confection. Once formed, the second phase was applied as a coating, in a standard dipping process, to form the second phase of solid fat-based confection as a coating.

[0056] The frozen confection products comprised 72.7 wt% of the first phase of frozen aerated confection and 27.3 wt% of the second phase of solid fat-based confection. Once formed sticks were inserted and a plastic wrapper applied. Subsequently a number of such prepared confections had their wrappers and sticks removed and placed in a large beaker.

[0057] The coated confections were broken apart by hand with a spatula in a bowl. Once the largest chocolate pieces were only up to 3cm long, the bowl was covered and placed in a 5°C refrigerator for cold melting.

[0058] Melting was continued until the first phase had completely melted and temperature reading was above 3°C. To decrease melting time or reduce viscosity of mix, cold water (below 5°C may be added as an optional step).

[0059] The ice cream / coating mix was transferred to a filtration sieve with pore size of 1 mm. Using a spatula, the mix was evenly distributed across the sieve and gently mixed to allow majority of ice cream mix to get through sieve leaving mostly chocolate pieces in the sieve. In alternative embodiments, the sieve may be static or vibrating, and / or a rotating sieve.

[0060] The ice cream mix that passed through the sieve was captured in a bowl and placed in the refrigerator for later reworking.

[0061] Using cold water (<5°C) any remaining ice cream is washed from the coating pieces. Using a spatula, the chocolate coating pieces were mixed so every surface was exposed to washing. This was repeated until no ice cream was visually left.

[0062] Then a cold (<5°C) nitrogen air gun was applied to dry the washed chocolate coating pieces by blowing any water with residual dissolved ice cream from the surface. This was continued until there was visually no water left on the coating pieces.

[0063] The coating pieces were then stored in an air-tight container and placed in a freezer for later reworking.

[0064] New. subsequent, frozen confection items, that were essentially identical to the initial coated ice cream confections, were then manufactured. The recovered ice cream and recovered coating pieces were reworked into the formulations during initial manufacture.

Claims

Claims1. A process of recovering ingredients of a frozen confection item, the recovered ingredients being used in the manufacture of a subsequent frozen confection item, wherein the frozen confection item comprises a first phase of frozen aerated confection, and a second phase of solid fat-based confection, the process comprising the steps of a) processing the frozen confection so that the first phase becomes flowable, but wherein the second phase remains solid; followed by b) sieving the processed frozen confection, such that the first phase passes through the sieve and the second phase does not pass through the sieve; followed by c) recovering the first phase and / or the second phase; followed by d) manufacturing a subsequent frozen confection item from ingredients that include at least a portion of the recovered first phase and / or second phase.

2. A process according to claim 1 , wherein the sieving is carried out at a temperature where the first phase is at least partially melted but wherein the second phase remains solid.

3. A process according to any one of the preceding claims, wherein the recovered first phase is flowable, to be used in the manufacture of the subsequent frozen confection in liquid form.

4. A process according to any one of the preceding claims, wherein the sieving step includes vibration of the sieve.

5. A process according to any one of the preceding claims, wherein the sieving step includes rotation of the sieve.

6. A process according to any one of the preceding claims, wherein the sieve has holes having an effective diameter of from 0.5 to 3mm.

7. A process according to any one of the preceding claims, wherein the first phase becomes flowable at a temperature in the range of from -10 to 10°C.

8. A process according to any one of the preceding claims, wherein the first phase comprises fat at a level of from 0 to 25 wt%.

9. A process according to any one of the preceding claims, wherein the first phase comprises ice cream.

10. A process according to any one of the preceding claims, wherein the second phase has a melting temperature in the range of from 10 to 50°C.

11. A process according to any one of the preceding claims, wherein the second phase comprises fat at a level of from 30 to 85 wt%.

12. A process according to any one of the preceding claims, wherein the second phase comprises chocolate or a chocolate analogue.

13. A subsequent frozen confection item comprising recovered first phase and / or second phase obtainable by the process of any of claims 1 to 12.

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