Cocoa powder substitute comprising fermented SOY okara and method for producing the same
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- MYCOSORTIA PTE LTD
- Filing Date
- 2026-01-30
- Publication Date
- 2026-08-06
Smart Images
Figure IB2026050899_06082026_PF_FP_ABST
Abstract
Description
Official OpenCOCOA POWDER SUBSTITUTE COMPRISING FERMENTED SOY OKARA AND METHOD FOR PRODUCING THE SAMEFIELD OF THE INVENTION
[0001] The present invention relates generally to the field of food science and sustainable ingredient production. More specifically, the present invention relates to a novel cocoa powder substitute derived from soy okara, and a method for preparing said cocoa substitute using controlled fermentation, alkalization, and flavor precursor supplementation. The present invention further relates to chocolate-like food products and confectionery compositions containing the cocoa substitute.BACKGROUND OF THE INVENTION
[0002] Cocoa flavor is a fundamental ingredient in a vast array of global food products, particularly within the confectionery, bakery, and beverage industries. Natural cocoa production is geographically restricted to the " Cocoa Belt," a narrow region spanning the Equator between 0 to 20 degrees north and south, which makes the global supply chain highly susceptible to climate change, regional pests, and diseases. Beyond geographic constraints, conventional cocoa cultivation is increasingly associated with negative environmental impacts, including significant carbon emissions, loss of biodiversity, and deforestation. Furthermore, ethical concerns regarding child labour on cacao farms and recent findings of heavy metal contamination — specifically lead and cadmium — in popular dark chocolate brands have intensified the search for safe, sustainable, and ethical alternatives.
[0003] The necessity for a viable cocoa substitute has been further accelerated by unprecedented market volatility. In recent years, cocoa prices have surged dramatically to $12000 per metric ton in 2024, by about 500% since 2022, due to various factors, including poor harvests in major producing countries like Ivory Coast and Ghana. The global cocoa stocks-to-consumption ratio has reached its lowest level in 47 years, exacerbating price volatility. This sharp rise in prices has put pressure on the confectionery industry to find alternative ingredients to maintain productOfficial Openaffordability and availability. These economic pressures necessitate the development of a substitute that can replace natural cocoa in cocoa-containing confectionery products, like chocolates.
[0004] The primary technical hurdle in creating a functional cocoa analogue is duplicating the complex physico-chemical and organoleptic profile of natural cocoa. Imitation products that deviate significantly from natural cocoa in terms of water-soluble carbohydrate content tend to be excessively hygroscopic and prone to premature "fat bloom" in confectionery coatings. Additionally, formulations with inconsistent fat contents can radically alter the viscosity of coatings, which is a critical parameter for industrial deposition processes. Many plant-based substitutes also suffer from undesirable "beany" or cereal-like off-flavors that fail to capture the sensory complexity of fermented and roasted cacao.
[0005] Various technical strategies have been proposed to address the challenges of generating cocoa-homologous flavors from non-cocoa sources. Early foundational methods, such as those described in US 2,835,590 and US 5,676,993, utilize the Maillard reaction between reducing sugars and specific amino acid precursors (e.g., phenylalanine, leucine, and valine) or peptides to generate characteristic chocolate volatiles. Advanced thermal processing, including microwave-assisted flavor generation, is further detailed in US 5,041,296.
[0006] To mimic the structural and sensory properties of cocoa solids, diverse plantbased matrices have been explored. For example, US 4,312,890 A describes the use of roasted food yeast, while more recent innovations leverage upcycled materials such as spent coffee grounds (US 2006 / 0222753 A1, US 11,259,551 B2, and US 11,918,008 B2), shea residues (WO 2018 / 226149 A1), wine lees (CN 109097194 A), and toasted jackfruit seeds (BR 102013019333 B1 ). Recent 2024-2025 developments have focused on high-lignin cacao waste products (e.g., shells and pods), as seen in WO 2025 / 145168 A1, which utilizes acid / base hydrolysis to improve the grindability and texture of the substitute.
[0007] The microbial and enzymatic transformation of legumes and seeds represents a significant trend in the current prior art. WO 2024 / 095016 A1 and WO 2023 / 126685 A1 (Nukoko) describe the fermentation of fava beans to degrade storage proteins intoOfficial Openpeptide precursors essential for cocoa aroma. Similarly, Planet A Foods (WO 2021 / 148418 A1) utilizes a combination of fermentation and low-temperature vacuum drying on sunflower seeds and oats to preserve precursors for roasting. Other plant compositions involve the use of carob (US 2018 / 0360067 A1 ), green banana flour (US 2019 / 0000121 A1), and complex flavor mixtures combining amino acids with various fermented plant materials (WO 2023 / 285547 A1). Finally, Barry Callebaut (WO 2025 / 003107) has addressed the textural aspects of cocoa-free alternatives by optimizing the fat-phase-to-milk-fat ratio to mimic the melting profile and crystal network of traditional chocolate.
[0008] Soy okara, a byproduct of soymilk and tofu manufacturing, represents a critical opportunity for sustainable material sourcing, as approximately 1.2 kilograms of okara are generated for every 1 kilogram of processed soybeans. However, the utilization of okara as a cocoa substitute is traditionally hindered by its high insoluble fiber content, which imparts a "sandy" or "gritty" mouthfeel, and its inherently "beany" off-notes.
[0009] Prior attempts to upcycle okara, such as JP 2015-027280 A, have focused on surface-level treatments, including alkali neutralization followed by roasting or the addition of external fermentation broth containing Saccharomyces cerevisiae or lactic acid bacteria. While these represent advances in upcycling, they rely on the external addition of flavor carriers rather than a fundamental biochemical transformation of the solid okara matrix itself. Furthermore, while the broader prior art has explored microbial fermentation of other legumes (e.g., fava beans in WO 2024 / 095016 A1) and the use of sunflower / oat matrices (WO 2021 / 148418 A1 ), these methods often struggle to resolve the structural fiber issues inherent to soy residues while simultaneously generating a complete cocoa-homologous volatile profile.
[0010] There remains a significant technical gap in combining the deep structural modification of a solid-state matrix with high-intensity precursor enhancement. The present invention addresses this by employing a complex solid-state fermentation (SSF) of okara using a specialized mixed culture of fungi, yeast, and lactic acid bacteria. Unlike the liquid-additive approach of JP 2015-027280 A, this triple-culture SSF fundamentally degrades the okara’s recalcitrant fiber and storage proteins in situ, generating a broad spectrum of endogenous peptides, free amino acids, and reducing sugars.Official Open
[0011] This bio-transformed matrix is further optimized through a synergistic integration with a legume-grain framework and the targeted fortification of selected amino acids and reducing sugars. Critically, while recent "upcycled" patents like Voyage Foods (WO 2025 / 145168 A1) utilize acid or base hydrolysis to improve friability, the present invention uniquely employs a high-alkaline adjustment (pH 9.0-11.0) specifically prior to roasting. This specific pH environment, combined with the enriched precursor pool from the mixed-culture SSF, accelerates the development of complex pyrazines and eliminates soy-derived off-flavors, resulting in a cocoa-free substitute that matches both the sensory profile and the physical mouthfeel of traditional cocoa powder. The resulting substitute is substantially free of cocoa solids, possesses a particle size of less than 250 pm, and achieves 100% pound-for-pound cocoa replacement in confectionery and beverage applications.SUMMARY OF THE INVENTION
[0012] In one aspect, the present invention provides a method for producing a cocoa powder substitute from soy okara.
[0013] In another aspect, the present invention provides a method for preparing a cocoa powder substitute comprising fermenting soy okara and subsequently roasting the fermented okara, or alternatively, blending the fermented okara with fermented or non-fermented beans and grains followed by roasting the resulting mixture.
[0014] In a further aspect, the present invention provides a method for enhancing the flavor profile of a cocoa powder substitute by incorporating flavor precursors — such as amino acids and reducing sugars — into the okara, bean, or grain mixtures, and subjecting the mixture to alkalization by adjusting the pH to a range of approximately 9 to 11 before roasting.
[0015] In another aspect, the present invention provides a method for preparing a cocoa powder substitute comprising the following steps:a. Pretreatment: Soaking beans and grains individually in an aqueous medium or an alkaline solution for at least 4 hours.Official Openb. Draining: Removing excess water from the soaked beans and grains.c. Sterilization: Individually sterilizing the soy okara, beans, and grains.d. Fermentation: Individually fermenting the sterilized okara, beans, and grains using a consortium of Generally Recognized as Safe (GRAS) microbial strains.e. Alkalization: Adjusting the pH of the fermented okara, beans, and grains to a range of 9 to 13.f. Dehydration: Individually dehydrating the fermented components to a moisture content of less than 10%.g. Roasting: Individually roasting the dehydrated okara, beans, and grains.h. Grinding: Separately grinding the roasted components to a powder having a particle size of less than 250 µm.i. Formulation: Mixing the roasted powders to formulate the cocoa powder substitute.j. Alternative Processing: As an alternative to individual processing, mixing fermented okara with fermented or non-fermented grains, beans, or combinations thereof prior to dehydration.k. Flavor Enhancement: Supplementing the mixture with flavor precursors, including but not limited to amino acids, peptides, protein hydrolysate, reducing sugars, biomass hydrolysates, to enhance chocolate-like aromatic profiles.l. Mixture Alkalization: The pH of the biotransformed mixture is adjusted to a range of 9.0 to 13.0; more preferably to a range of 9.0 to 12.0; and most preferably to a range of 9.0 to 11.0.m. Mixture Dehydration: The mixture is dehydrated to a residual moisture content of less than 15% by weight; more preferably, less than 12% by weight; and most preferably, less than 10% by weight.Official Openn. Mixture Roasting: The dehydrated mixture is roasted to develop cocoa- homologous color and aroma profile at a temperature of 110°C to 180°C for 5 to 90 minutes; more preferably at 120°C to 170°C for 10 to 70 minutes; even more preferably at 130°C to 160°C for 15 to 60 minutes; and most preferably at 140°C to 150°C for 15 to 50 minutes.o. Final Milling: The roasted material is ground to a fine powder with a particle size distribution where the average particle size is less than 500 µm; more preferably, less than 350 µm; and most preferably, less than 250 µm.
[0016] The methodology of the present invention is further illustrated in the schematic representation provided in Figure 1.
[0017] In another aspect, the present invention provides a composition for a chocolate-like food product comprising the aforementioned cocoa powder substitute, fat, and sugar.
[0018] In a further aspect, the invention provides a chocolate-like product characterized by high dietary fiber and reduced sugar content, enabled by the integration of the soy okara-based cocoa powder substitute.
[0019] In yet another aspect, the present invention relates to a method of preparing chocolate-like food products — including bars, spreads, and confectionery — using the cocoa powder substitute, optionally incorporating a conching process to refine the texture and enhance the synergistic chocolate flavor.BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Figure 1 is a schematic flow diagram illustrating the various embodiments of the method for preparing the cocoa powder substitute, including individual processing, composite processing, and precursor-enhanced processing pathways.
[0021] Figure 2 is a spider plot (radar chart) illustrating the comparative sensory profile of a milk chocolate alternative comprising a 60% weight substitution of natural cocoa with the cocoa powder substitute of the present invention.Official Open
[0022] Figure 3 is a spider plot illustrating the comparative sensory profile of a milk chocolate alternative comprising a 100% weight substitution of natural cocoa with the cocoa powder substitute of the present invention.
[0023] Figure 4 is a spider plot illustrating the comparative organoleptic profile of a Dubai-style chocolate alternative formulated with 100% cocoa substitution, demonstrating the flavor compatibility of the present invention in high-fat, specialty confectionery applications.DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention provides a cocoa powder substitute comprising soy okara, and optionally further comprising one or more varieties of beans and grains. The resulting cocoa powder substitute exhibits a texture, color, and flavor profile substantially similar to conventional cocoa powder.I. Pretreatment of Raw Materials
[0025] In accordance with the present invention, the raw materials — specifically grains and beans — undergo a rigorous pretreatment process to prepare them for fermentation.
[0026] In one embodiment, the beans and grains are soaked in an aqueous medium for a period of approximately 4 to 24 hours, preferably 8 to 18 hours, and more preferably 10 to 12 hours. The soaking medium is selected from tap water, distilled water, or an alkaline solution having a pH in the range of 8 to 13 using food-grade sodium carbonate, potassium carbonate, or sodium hydroxide.
[0027] Suitable grains for use in the invention include, but are not limited to, wheat, buckwheat, rice, oats, barley, millet, sorghum, and corn. Suitable beans include, but are not limited to, soybeans, mung beans, peas, urad beans, lentils (e.g., Beluga lentils or azuki beans), kidney beans (Rajma), fava beans, black beans, pinto beans, chickpeas, black-eyed peas, navy beans, lima beans, cannellini beans, white hyacinth beans, and great northern beans.Official Open
[0028] Following soaking, the beans and grains are drained. The soy okara, beans, and grains are then sterilized to eliminate indigenous microbial load, ensuring a clean substrate for controlled fermentation. Sterilization is preferably achieved via pressurized steam (autoclaving), or steaming at atmospheric pressure.II. Controlled Fermentation
[0029] As depicted in Figure 1, the sterilized substrates (okara, beans, or grains) are inoculated with Generally Recognized as Safe (GRAS) microbial strains. In preferred embodiments, the microorganisms are selected from the group consisting of filamentous fungi, yeast, and lactic acid bacteria. Fermentation is conducted at temperatures and durations optimized for the specific strain (e.g., 25-50°C for 24-72 hours) to enzymatically break down complex polysaccharides and proteins, thereby developing the primary flavor base.III. Alkalization and Flavor Precursor Enhancement
[0030] A characterizing feature of the present invention is the post-fermentation enhancement step. To achieve the deep color and reduced acidity characteristic of alkalized cocoa (Dutch-process), the fermented substrate is subjected to a pH adjustment.
[0031] In one embodiment, fermented okara, beans, and grains are adjusted to pH 9.0-13.0, more preferably 9.0-12.0, and most preferably 9.0-11.0. This is achieved using food-grade alkalis, such as potassium carbonate, sodium bicarbonate, or sodium hydroxide.
[0032] Furthermore, the present invention provides the addition of flavor precursors to the mixture. These precursors comprise amino acids, peptides, protein hydrolysates, reducing sugars, and plant biomass hydrolysates. During the subsequent roasting stage, these precursors facilitate Maillard reactions and Strecker degradation, resulting in the formation of pyrazines and other aromatic compounds that provide the "chocolate" sensory profile.IV. Dehydration, Roasting, and Milling
[0033] The processing sequence follows several optional embodiments:Official Opena. Individual Processing: Fermented and alkalized components are individually dehydrated to a moisture content of less than 10%, roasted at 100°C to 180°C, and milled.b. Composite Processing: Fermented okara is blended with other fermented or non-fermented components before heat treatment.c. Precursor-Enhanced Processing: The combined mixture is supplemented with the aforementioned flavor precursors and alkalized to pH 9.0-13.0 before undergoing dehydration and roasting.
[0034] The final roasted material is ground to a fine powder with a particle diameter of less than 250 µm, to achieve up to 100% pound-for-pound cocoa replacement in confectionery and beverage applications.V. Food Product Compositions
[0035] The cocoa powder substitute described herein is utilized to formulate chocolate-like food products. A typical composition comprises:a. 5% to 50% by weight of the cocoa powder substitute;b. a fat source selected from cocoa butter, vegetable fats, or hydrogenated oils;c. sweeteners such as sucrose, polyols, or high-intensity sweeteners.
[0036] Due to the high fiber content of the soy okara and beans, the resulting products are characterized as "high-fiber" and "reduced-sugar" alternatives to traditional chocolate. Optional additives include emulsifiers (e.g., lecithin), milk solids, and flavoring agents (e.g., vanillin).VI. Manufacturing of Confectionery
[0037] In one embodiment, the invention relates to a method for producing chocolatelike products through a conching process. The mixture of the cocoa powder substitute, fats, and sweeteners is conched at a temperature between 25°C and 60°C for a duration of 12 to 96 hours.Official Open
[0038] In a specific application, the invention provides a method for producing a confectionery bar (e.g., " Dubai-style" chocolate), comprising:a. preparing a crunchy filling by combining fried okara with pistachio paste, or hazel nut paste, sugar, milk powder, and vegetable oil; andb. enrobing or molding said filling with a refined chocolate-like mixture containing the okara-derived cocoa substitute.
[0039] The resulting products include, but are not limited to, spreads, bars, truffles, beverages, and baked goods.EXAMPLES
[0040] The present invention will be described in more detail with reference to the following examples. These examples are provided only to illustrate the present invention and should not be construed as limiting the scope and spirit of the present invention.Example 1. Pretreatment of Beans and Grains
[0041] A 100-gram sample of each bean or grain variety was initially washed with tap water to remove debris. The samples were subsequently soaked for a minimum of four hours to ensure complete swelling, utilizing either tap water or an alkaline solution adjusted to a pH of 10-13 with food-grade sodium carbonate. Following the soaking period, each sample was individually steam -sterilized at atmospheric pressure for 30 minutes using a dedicated steamer.Example 2. Cocoa Powder Substitute Derived from Alkali-Treated Fermented Beans
[0042] The pH of the fermented beans was adjusted to a range of 9-11 using foodgrade sodium carbonate. The beans were sterilized in a dedicated steamer and then dehydrated in an oven at 60 °C until the moisture content was reduced to less than 10%. The dehydrated beans were roasted at 140 °C for 25 minutes before being ground into a fine powder with a particle size of less than 250 micrometers.Official OpenExample 3. Cocoa Powder Substitute Derived from Alkali-Treated Fermented Grains
[0043] The pH of the fermented grains was adjusted to a range of 9-11 using foodgrade sodium carbonate. Subsequently, they were individually dehydrated in an oven at 60 °C until their moisture content reached less than 10%. The dehydrated grains were then roasted at 140 °C for 15 minutes. Finally, the roasted grains were individually ground into a fine powder using a ball mill, achieving a particle size of less than 250 micrometers.
[0044] The pH of the fermented grains was adjusted to a range of 9-11 using foodgrade sodium carbonate. These grains were dehydrated in an oven at 60 °C until the moisture content fell below 10%. Following dehydration, the grains were roasted at140 °C_for 15 minutes and ground using a grinder to achieve a particle size of less than 250 micrometers.Example 4. Okara Fermentation Process
[0045] Sterilized soybean okara (200 g) was inoculated with 0.1 -0.3% (w / w) of a microbial consortium starter culture. This culture comprised fungal strains selected from Aspergillus oryzae, Rhizopus oligosporus, R. oryzae, Mucor rouxianus, M. racemosus, or M. circinelloides', a commercial lactic acid bacteria mixture containing Lactobacillus delbrueckii subsp. bulgaricus and Streptococcus thermophilus', and a yeast mixture selected from Saccharomyces cerevisiae, Saccharomyces bayanus, Candida utilis, or Torulaspora delbrueckii. The mixture was thoroughly mixed and fermented in cloth-covered containers at 20-50 °C for 18-72 hours. The resulting fermented okara was either utilized immediately or preserved by freezing.Example 5. Cocoa Powder Substitute Derived from Fermented Soy Okara
[0046] The fermented okara was dehydrated in an oven at 60°C for 12 hours to achieve a moisture content of less than 10%. The material was then roasted at 140°C for 25 minutes and milled to a particle size of less than 250 µm. The resulting powder serves as a direct cocoa powder substitute or as a blending component with fermented or unfermented bean and grain powders for chocolate-like formulations.Official OpenExample 6. Cocoa Powder Substitute Derived from Fermented Soy Okara with Flavor Precursors
[0047] A 200 g sample of fermented okara was supplemented with flavor precursors comprising 0.8 g phenylalanine, 0.5 g leucine, 0.2 g alanine, and 0.6 g glucose. The mixture's pH was adjusted to 10 using sodium carbonate. The composition was dehydrated at 60°C for 12 hours to a moisture content below 10%, roasted at 140°C for 25 minutes, and ground to a particle size of less than 250 µm.Example 7. Bean Fermentation Process
[0048] Samples consisting of 100 grams of sterilized beans were individually inoculated with the starter culture described in Example 4 at a dosage of 0.1 -0.3%. After thorough mixing, the inoculated beans were placed in cloth-covered containers and fermented at 20-50 °C for 18-72 hours. The fermented beans were harvested for immediate use or stored under frozen conditions.Example 8. Cocoa Powder Substitute Derived from Fermented Beans
[0049] Fermented beans were dehydrated at 60 °C for 12 hours until the moisture content reached less than 10%. The beans were then roasted at 140 °C for 20 minutes and ground into a fine powder with a particle size of less than 250 micrometers.Example 9. Cocoa Powder Substitute Derived from Fermented Beans with Flavor Precursors
[0050] A 100 g sample of fermented beans was supplemented with 2.0 g phenylalanine, 1.0 g leucine, 0.3 g glutamic acid, 0.1 g isoleucine, and 3.0 g glucose. The mixture was mixed, and the pH was adjusted to 10 using sodium carbonate. The preparation was dehydrated at 60°C for 12 hours to a moisture content of less than 10%, roasted at 140°C for 20 minutes, and ground to a particle size of less than 250 µm.Example 10. Grain Fermentation Process
[0051] Individual 100-gram samples of sterilized grains were inoculated with the starter culture defined in Example 4 at a dosage of 0.1 -0.3% (w / w). FollowingOfficial Openthorough mixing, the grains were fermented in cloth-covered containers at 20-50 °C for 18-72 hours. The fermented grains were then harvested and either used immediately or stored in a freezer.Example 11. Cocoa Powder Substitute Derived from Fermented Grains
[0052] Fermented grains were dehydrated at 60 °C for 12 hours to achieve a moisture content of less than 10%. Subsequently, the grains were roasted at 140 °C for 15 minutes and ground to a particle size of less than 250 micrometers.Example 12. Cocoa Powder Substitute Derived from Fermented Grains with Flavor Precursors
[0053] A 100 g sample of fermented grains was mixed with flavor precursors, specifically 1.0 g phenylalanine, 2.0 g leucine, 1.0 g glutamic acid, 0.5 g isoleucine, and 2.0 g glucose. The pH was adjusted to 10 using sodium carbonate. The mixture was dehydrated at 60°C for 12 hours to a moisture content under 10%, roasted at 140°C for 15 minutes, and ground to a particle size of less than 250 µm.Example 13. Cocoa Powder Substitute Derived from a Mixture of Fermented Soy Okara and Alkali-treated Beans
[0054] One hundred grams of fermented okara was blended with 100 grams of individually sterilized alkali-treated beans. The resulting mixtures were dehydrated at 60 °C for 12 hours until the moisture content was less than 10%. After roasting at 140 °C for 25 minutes, the mixtures were ground to a fine powder with a particle size of less than 250 micrometers.Example 14. Cocoa Powder Substitute Derived from a Mixture of Fermented Soy Okara and Alkali-treated Grains
[0055] Fifty grams of fermented okara was combined with 100 grams of individually sterilized, alkali-treated grains. These mixtures were dehydrated at 60 °C for 12 hours to a moisture content of less than 10%, roasted at 140 °C for 15 minutes, and ground to a particle size of less than 250 micrometers.Official OpenExample 15. Cocoa Powder Substitute Derived from a Mixture of Fermented Soy Okara with Alkali-Treated Beans and Grains
[0056] Two hundred grams of fermented okara was mixed with 100 grams of sterilized, alkali-treated beans and 100 grams of alkali-treated grains. The composite was dehydrated at 60 °C for 12 hours until the moisture content was less than 10%, then roasted at 140 °C for 25 minutes and ground to a particle size of less than 250 micrometers.Example 16. Cocoa Powder Substitute Derived from a Mixture of Fermented Soy Okara and Fermented Beans
[0057] One hundred grams of fermented okara was blended with 100 grams of individually fermented beans. The resulting mixtures were dehydrated at 60 °C for 12 hours until the moisture content was less than 10%. After roasting at 140 °C for 25 minutes, the mixtures were ground to a fine powder with a particle size of less than 250 micrometers.Example 17. Cocoa Powder Substitute Derived from a Mixture of Fermented Soy Okara and Fermented Grains
[0058] Fifty grams of fermented okara was combined with 100 grams of individually fermented grains. These mixtures were dehydrated at 60 °C for 12 hours to a moisture content of less than 10%, roasted at 140 °C for 15 minutes, and ground to a particle size of less than 250 micrometers.Example 18. Cocoa Powder Substitute Derived from a Mixture of Fermented Soy Okara with Fermented Beans and Grains
[0059] Two hundred grams of fermented okara was thoroughly mixed with 100 grams of fermented beans and 100 grams of fermented grains. The pH of the mixture was adjusted to 10 using sodium carbonate. The blend was dehydrated at 60 °C for 12 hours to a moisture content of less than 10%, roasted at 140 °C for 25 minutes, and ground to a particle size of less than 250 micrometers.Example 19. Cocoa Powder Substitute Derived from a Mixture of Fermented Soy Okara with Fermented Beans, Grains, and Flavor PrecursorsOfficial Open
[0060] Two hundred grams of fermented okara was blended with 100 grams of sterilized, fermented beans and 100 grams of fermented grains. This mixture was supplemented with flavor precursors, including 1.6 g phenylalanine, 2.4 g leucine, 0.4 g isoleucine, and 4.0 g glucose. The pH was adjusted to 10 with sodium carbonate. The mixture was then dehydrated at 60 °C for 12 hours to a moisture content below 10%, roasted at 140 °C for 25 minutes, and ground to a particle size of less than 250 micrometers.Example 20. Chocolate-like Bars Prepared from Fermented Okara and Individual Beans or Grains
[0061] Forty grams of cocoa butter substitute (CBS) were melted in a water bath. To this, 15 grams of a selected fermented substrate (okara, individual beans, or grains), 25 grams of icing sugar, 19.6 grams of full-cream cow milk powder, and 0.4 grams of soy lecithin were added and blended until uniform. The mixture was cast into molds and solidified to produce chocolate-like bars. Sensory profiles were evaluated by a trained panel (n=4) using a 1-10 scale across attributes including color, sweetness, bitterness, sourness, astringency, maltiness, chocolatiness, nuttiness, and overall likeability, the results of which are detailed in Table 1.Table 1. Sensory profile of chocolate-like bars made using fermented okara, individual fermented beans, or grainsCocoa Color Sweet Bitter Sour Astringent Malty Chocolaty Nutty Overall powder (dark) likeability substituteF-okara 5.5 5.5 2 1 2.5 2 4.6 6 5.5F- 3.5 6 0 1 2.5 6 6.5 5 6.75 soybeanF-fava 8 7 4 1 2 5.5 7.25 6 7.25 beanOfficial OpenF-oats 2 7 1 1 1 5 4.5 3 4.25F-pea 5 6.5 1.5 2 3 4.5 6.25 5.5 7.25F-azuki 10 7.5 2 0.5 0.5 5 7.5 5 7.5 beanF-white 4.5 6.25 1.5 2.5 2 5 4.5 3.5 5.5 kidneybeanF- Lablab 5 6 1.5 1 3.5 5 5.5 5 6.5 PurpureusNote: “F” stands for “fermented”.Example 21. Chocolate-like Bars Prepared from a Mixture of Fermented Okara and Individual Fermented Beans or Grains
[0062] Following the melting of 40 grams of CBS, a mixture containing 5 grams of fermented okara and 10 grams of a fermented bean or grain was added, alongside 25 grams of icing sugar, 19.6 grams of full-cream cow milk powder, and 0.4 grams of soy lecithin. The composition was homogenized with a hand blender, molded, and allowed to solidify. Sensory evaluations (n=4) were conducted on a 1-10 scale, with data regarding the flavor and texture profiles summarized in Table 2.Table 2. Sensory profile of chocolate-like bars made using a mixture of fermented okara and an individual fermented bean or an individual fermented grain.F-okara Color Sweet Bitter Sour Astringent Malty Chocolaty Nutty Overall with likeability fermentedbean orgrainF- 3.5 7.25 2 1 2 6 7 6 7.5 soybeanOfficial OpenF-fava 4 6.75 3 2 1 5.5 7 4.5 7.25 beanF-oats 2 7 0 1.5 1.5 6 5 4.5 5F-pea 3.5 6.75 0 0.5 4 5 5.75 5 6F-azuki 6 7.25 0 0.5 3 5.5 7.125 6 7.125 beanF-white 4 7.75 1 0 4.5 5.5 2.5 4 7 kidneybeanF- Lablab 4.75 8 2.5 0 2 6 7.5 4.5 7.25 PurpureusNote: “F” stands for “fermented”.Example 22. Chocolate-like Bars Prepared from a Mixture of Fermented Okara, Fermented Beans, and Fermented Grains
[0063] Forty grams of CBS were melted via water bath, and a mixture of 5 grams of fermented okara, 5 grams of fermented bean, and 5 grams of fermented grain was incorporated. Additional ingredients included 25 grams of icing sugar, 19.6 grams of full-cream cow milk powder, and 0.4 grams of soy lecithin. After blending until uniform, the mixture was molded and solidified. Sensory results from a four-member panel are presented in Table 3.Table 3. Sensory profile of chocolate-like bars made using the mixture of fermented okara and an individual fermented bean, and an individual fermented grain.F-okara with Color Sweet Bitter Sour Astringent Malty Chocolaty Nutty Overall F-bean and likeability F-grainOfficial OpenF- 2 6.75 0 1 1.5 6.5 5.5 4.5 6 soybean+F- oatsF-fava 3 7.25 2.5 1 3.5 3.5 5.75 5 6 bean+F-oatsF-pea+F-oats 3 7.25 1.5 2 2.5 6 7.25 5.75 7.25F-azuki 6 7.5 0.5 0 2 5.5 7 6.5 7 bean+F-oatsF-white 2.5 7.5 1 2 1.5 6 6.25 4.5 6.25 kidneybean+F-oatsF- Lablab 2.4 7 1.5 2 3 6 7 4.5 7 Purpureus+F- oatsNote: “F” stands for “fermented”.Example 23. Chocolate-like Bars Prepared from Alkali-Treated Okara, Beans, and Grains
[0064] Forty grams of CBS were melted and combined with 15 grams of an alkali- treated substrate (either fermented okara, a mixture of okara with alkali-treated beans / grains, or individual alkali-treated fermented legumes / grains). The formulation was completed with 25 grams of icing sugar, 19.5 grams of full-cream cow milk powder, and 0.5 grams of soy lecithin. After homogenization and solidification in molds, the sensory performance was assessed (n=4) and recorded in Table 4.Official OpenTable 4. Sensory profile of chocolate-like bars made using alkali-treated okara, beans, and grainsCocoa Color Sweet Bitter Sour Astringent Malty Chocolaty Nutty Overall powder likeability substituteAkF-okara 2 7 1 1.5 2 5 6.5 4.5 7F- 7 6 6 2 3 3 7 5 7 okara+Ak- soybeanAkF- 4.25 6.75 2 1 4.5 5 5.5 6 6 soybeanF- 1 7.75 0 0 2 5 6.5 3 6.5 okara+Ak- fava beanAkF-fava 8.75 7.25 4.5 0 2.5 5.5 7.5 6.5 7.5 beanF- 7 7.5 0.5 0 2 5.5 7.5 5.5 7.5 okara+Ak- azuki beanAkF-azuki 10 7 6.5 1 4 4.5 7 6 7 beanF- 2 6.75 0 0 1.5 5 6.5 4.5 7 okara+Ak- peaAkF-pea 8 7 1.75 1 2 5.5 7 6.75 7F- 1 8 0 0 1.5 5.5 4.5 3.5 6 okara+Ak- oatsOfficial OpenAkF-oats 7.75 6.26 5 1.5 3 5.5 7.75 6.5 8Note: “F” stands for “fermented”, “Ak” stands for “alkali-treated”, “AkF” stands for “alkali-treated fermented”.Example 24. Chocolate-like Bars Prepared Using pH-Adjusted Cocoa Butter Substitutes with and without Flavor Precursors
[0065] Forty grams of CBS were melted, and 15 grams of the prepared cocoa powder substitute were added along with 25 grams of icing sugar, 19.6 grams of full-cream milk powder, and 0.4 grams of soy lecithin. The mixture was processed and molded as previously described. Sensory evaluation (n=4) compared formulations with and without flavor precursors across various metrics, as summarized in Table 5.Table 5. Sensory profile of chocolate-like bars made using the mixture of fermented okara, beans and grains, with pH adjustment and with and without precursors Cocoa powder Color Sweet Bitter Sour Astringent Malty Chocolaty nutty Overall substitute likeability Okara+alkali 1.5 5 5 3.5 3 3.5 1 2.5 2 Okara + 6.5 4.5 1 1.5 2 4 3.25 1.5 4.5 precursors+alkaliF-okara+alkali 7 4.5 2.5 4 3 3.5 1.5 2 2 F-okara+alkali 7 5.25 1.5 2 1.5 4.5 3.5 1.5 4.5 +precursorsF-okara+F- 9 5 2 2 3 4 5 4.5 6 pea+F- oats+alkaliF-okara+F- 9 6 2 1.5 2 4.5 6.25 4.5 7.25 pea+F-oatsOfficial Open+alkali+precursorse: “F” stands for “fermented”, “Ak” stands for “alkali-treated”, “AkF” stands for “alkali- treated fermented”.Example 25. Milk Chocolate Alternative with 60% Cocoa Powder Substitute
[0066] Two hundred and forty grams of CBS were melted in a 2-L conching machine. The following ingredients were added: 137.1 grams maltitol, 42 grams cocoa powder, 60 grams cocoa powder substitute (comprising 15 g fermented okara, 25 g fermented pea, and 10 g fermented oats), 117 grams full-cream milk powder, 1.5 grams vanilla extract, and 2.4 grams soy lecithin. Conching was performed at 30-50 °C for 16-48 hours before molding and solidification. Sensory assessment results (n=13, 1-9 scale) are presented in Figure 2.Example 26. Milk Chocolate Alternative with 100% Cocoa Powder Substitute
[0067] In a 2-L conching machine, 204 grams of CBS were melted. Sixty grams of 100% cocoa powder substitute (20 g fermented okara, 15 g fermented pea, 15 g fava bean, and 10 g oats) were added along with 186 grams castor sugar, 145.6 grams fullcream milk powder, 2.1 grams flavoring, and 2.4 grams soy lecithin. The mixture underwent conching at 30-50 °C for 16-48 hours. The resulting bars were evaluated by a sensory panel (n=13) across multiple attributes, with data summarized in Figure 3.Example 27. Dubai-Style Chocolate Alternative (100% Cocoa Replacement) with Okara Filling
[0068] To prepare the Dubai-style chocolate alternative, a plant-based cocoa powder substitute was formulated by blending 30 g fermented okara, 40 g fermented soybean, 20 g fermented fava bean, and 10 g fermented oats. Simultaneously, 200 g of CBS was melted in a double boiler. The cocoa substitute, 150 g icing sugar, and 2.5 g soy lecithin were integrated into the CBS using high-speed mixing to ensure homogeneity.Official OpenThe mixture was conched at 35°C for 12-48 hours to remove moisture and volatile acids, then cooled for molding.
[0069] The filling was prepared by mixing fermented okara with wheat flour and tossing the mixture in melted butter. This was cooked over medium heat until golden-brown and crispy. Separately, 50 g of pistachios were roasted at 180°C till golden brown and processed into a smooth paste. The pistachio paste was folded into the crispy okara. To assemble, a thin chocolate shell was molded, filled with the pistachio-okara mixture, and sealed with a final layer of the chocolate alternative. After solidification in a refrigerated environment, sensory profiles (n=13) were evaluated and recorded as shown in Figure 4.
Claims
Official OpenCOCOA POWDER SUBSTITUTE COMPRISING FERMENTED SOY OKARA AND METHOD FOR PRODUCING THE SAMECLAIMS1. A cocoa powder substitute comprising at least a fermented soy okara, or a mixture of the fermented soy okara with at least one of a bean and a grain,2. A method for producing the cocoa powder substitute according to claim 1, comprising the steps of:a. Pretreatment: Soaking beans and grains individually in an aqueous medium or an alkaline solution for at least 4 hours;b. Draining: Removing excess water from the soaked beans and grains;c. Sterilization: Individually sterilizing the soy okara, beans, and grains;d. Fermentation: Individually fermenting the sterilized okara, beans, and grains using a microbial consortium of Generally Recognized as Safe (GRAS) strains;e. Alkalization: Adjusting the pH of the fermented okara, beans, and grains to a range of 9 to 13;f. Dehydration: Individually dehydrating the fermented components to a moisture content of less than 10% by weight;g. Roasting: Individually roasting the dehydrated okara, beans, and grains;h. Grinding: Separately grinding the roasted components to a powder having a particle size of less than 250 pm; andi. Formulation: Mixing the roasted powders to formulate the cocoa powder substitute.Official Open3. The method according to claim 2, further comprising an alternative processing step wherein the fermented okara is mixed with fermented or non-fermented grains, beans, or combinations thereof before the dehydration step (f).
4. The method according to claim 2, wherein the grains include, but not limited to, wheat, buckwheat, rice, oats, barley, millet, sorghum, and corn.
5. The method according to claim 2, where in the beans include, but not limited to, soybeans, mung beans, peas, urad beans, lentils (e.g., Beluga lentils or azuki beans), kidney beans (Rajma), fava beans, black beans, pinto beans, chickpeas, black-eyed peas, navy beans, lima beans, cannellini beans, white hyacinth beans, and great northern beans.
6. The method according to claim 2, further comprising a flavor enhancement step comprising supplementing the mixture with flavor precursors selected from the group consisting of amino acids, peptides, protein hydrolysates, reducing sugars, biomass hydrolysates, and combinations thereof.
7. The method according to claim 6, wherein the flavor precursors include at least one amino acid selected from the group consisting of leucine, phenylalanine, isoleucine, glutamic acid, alanine, glycine, lysine, and valine.
8. The method according to claim 6, wherein the flavor precursors include at least one reducing sugar selected from the group consisting of glucose, fructose, galactose, mannose, sorbose, gulose, idose, talose, allose, and altrose, arabinose, ribose, rhamnose, and xylose.
9. The method of claim 2, wherein the flavor precursors comprise a weight ratio of reducing sugars to free amino acids in the range of 5: 1 to 1:5.
10. The method according to claim 2, wherein the soaking in step (a) is conducted for 4 to 24 hours.
11. The method according to claim 2, wherein the sterilization In step (c) is conducted at 121 °C for at least 15 minutes or at 100 °C and atmospheric pressure for 30 to 60Official Openmin.
12. The method according to claim 2, wherein the microbial consortium in step (d) comprises at least one fungal strain, at least one yeast strain, and at least one lactic acid bacteria strain.
13. The method according to claim 12, wherein the fungal strain is selected from the group consisting of Aspergillus spp., Fusarium spp., Monascus spp., Mucor spp., Neurospora spp., Penicillium spp., Rhizopus spp., and combinations thereof.
14. The method according to claim 12, wherein the yeast strain is selected from a group consist of Candida sp., Debaryomyces spp., Hanseniaspora spp., Hansenula spp., Kloeckera spp., Kluyveromyces spp., Pichia spp., Rhodotorula spp., Saccharomyces spp., Saccharomycopsis spp., Schizosaccharomyces spp., Torulopsis spp., Yarrowia spp., and or any combinations thereof.
15. The method according to claim 12, wherein the lactic acid bacteria strain is selected from the group consisting of Bifidobacterium spp., Enterococcus spp., Lactobacillus spp., Lactococcus spp., and Streptococcus spp., and combinations thereof.
16. The method according to claim 2, wherein the fermentation in step (d) is conducted at 20 °C to 50 °C for 18 to 72 hours.
17. The method according to claim 2, wherein the dosage of the microbial consortium in step (d) is 0.1% to 0.5% (w / w).
18. The method according to claim 2, wherein the alkalizing agent in step (e) is selected from the group consisting of sodium carbonate, sodium bicarbonate, potassium carbonate, potassium bicarbonate, and combinations thereof.
19. The method according to claim 2, wherein the pH in step (e) is adjusted to a range of 9 to 12.
20. The method according to claim 19, wherein the pH is adjusted to a range of 9 to 11.Official Open21. The method according to claim 2, wherein the roasting in step (g) is conducted at 110 °C to 180 °C.
22. The method according to claim 21, wherein the roasting temperature is 130 °C to 160 °C.
22. The method according to claim 21, wherein the roasting temperature is 140 °C to 150 °C.
23. The method according to claim 2, wherein the duration of roasting in step (g) is 5 to 90 minutes.
24. The method according to claim 23, wherein the duration is 20 to 50 minutes.
25. A chocolate-like food product comprising:(a) the cocoa powder substitute according to claim 1;(b) a vegetable-derived fat or fat substitute;(c) a sweetener; and(d) optionally, a milk-derived or plant-based milk powder.
26. The chocolate-like food product according to claim 25, wherein the cocoa powder substitute replaces 60% to 100% of natural cocoa solids by weight.
27. The chocolate-like product according to claim 25, wherein the fat substitute is a vegetable-derived fat mimicking the melting profile of cocoa butter.
28. The chocolate-like product according to claim 25, wherein the fat is selected from the group consisting of shea butter, mango kernel fat, palm oil, coconut oil, vegetable oils, and combinations thereof.
29. The chocolate-like food product according to claim 25, further comprising at least one sweetener selected from the group consisting of sucrose, fructose, glucose, stevia, monk fruit, sugar alcohols, and combinations thereof.
30. The chocolate-like food product according to claim 25, further comprising at least one emulsifier selected from the group consisting of lecithin, polyglycerolOfficial Openpolyricinoleate (PGPR), and ammonium phosphatides.
31. The chocolate-like food product according to claim 25, further comprising at least one flavoring agent.
32. The chocolate-like food product according to claim 31, wherein the flavoring agent is selected from the group consisting of vanilla, fruit flavors, citrus flavors, spices, nut flavors, mint, and combinations thereof.
33. The chocolate-like food product according to claim 25, wherein the product is selected from the group consisting of chocolate spreads, chocolate bars, chocolate balls, chocolate truffles, Dubai-style chocolates, chocolate beverages, chocolate cakes, and chocolate cookies.
34. A method for producing the chocolate-like food product of claim 25, comprising preparing a chocolate mixture containing the cocoa powder substitute, a sweetener, a fat, and optionally a milk powder.
35. The method according to claim 34, further comprising a conching process conducted at 25 °C to 60 °C for 12 to 96 hours.
36. A method for producing a confectionery item, comprising:(a) preparing a crunchy filling by combining a fried mixture of fermented okara and wheat flour with a nut paste; and(b) coating the filling with the refined chocolate mixture of claim 33 using a chocolate moulding process.