Low-Moisture Caramel for Complex Confection Shapes
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Manufacturing multi-textured confections with caramel and crisp components is challenging due to moisture migration issues, and existing methods require additional processing time and equipment, limiting the production of complex shapes.
Innovation Solution
A caramel composition using solid plant fat with less than 10% water, which provides a chewy texture and is processable, eliminating the need for a moisture barrier and enrobing technology, allowing for the production of complex shapes without compromising taste or texture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fat-based moisture barrier is provided between high moisture and crisp components, then moisture migration is prevented, but processing time and equipment complexity increase
Solution Approach 1:
The patent removes the separate moisture barrier layer entirely by incorporating moisture-blocking functionality directly into the caramel component through reduced water content and specific fat selection. This eliminates the need for an additional barrier layer and its associated processing steps.
Solution Approach 2:
The moisture barrier function is merged with the caramel component itself. The caramel is formulated with less than 10% water and specific fat content to inherently prevent moisture migration, combining the barrier function with the filling component rather than using separate layers.
2Reliability
If a fat-based moisture barrier is provided between high moisture and crisp components, then moisture migration is prevented, but device complexity increases
Solution Approach 1:
The patent eliminates the need for specialized equipment to apply and maintain separate moisture barrier layers by incorporating moisture-blocking properties directly into the caramel formulation, thereby simplifying the manufacturing equipment requirements.
Solution Approach 2:
The caramel component is self-sufficient in preventing moisture migration through its inherent formulation (less than 10% water, specific fat content), eliminating the need for additional equipment to apply external barrier layers.
3Ease of manufacture
If enrobing manufacturing practices are used for stiffer caramels, then processability is improved, but shape versatility is limited to squares and rectangles
Solution Approach 1:
The patent modifies the physical parameters of the caramel by controlling water content (less than 10%) and fat content (15-30%), which adjusts the caramel's stiffness and processability to enable both efficient manufacturing and complex shape formation without enrobing.
Solution Approach 2:
Instead of making complex shapes difficult through traditional enrobing of stiff caramels, the patent inverts the approach by formulating the caramel with specific parameters that inherently enable complex shape deposition during manufacturing.
4Ease of manufacture
If liquid fat is used to render caramel more processable, then processability is improved, but texture becomes softer than desirable
Solution Approach 1:
The patent optimizes the fat content parameter (15-30%) and water content (less than 10%) to achieve a balance where the caramel remains processable while maintaining the desired chewy texture, avoiding the overly soft texture that results from using liquid fats.
Solution Approach 2:
The patent uses a composite formulation combining specific types of fats (including solid plant fats) with controlled water content to achieve both processability and desired texture, rather than relying solely on liquid fats.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The caramel composition ensures minimal moisture migration, maintains desired organoleptic properties, and allows for efficient processing and deposition of complex shapes, extending shelf life and reducing texture deterioration in confections.
Implementation Method 1
a caramel composition using solid plant fat with less than 10% water, which provides a chewy texture and is processable
Implementation Method 2
even though the caramel comprises up to 10% water, confections comprising the caramel and a crisp component do not exhibit undesirable levels of, or any, moisture migration from the caramel to the crisp component
Data Source
AI summary
A caramel is provided comprising a solid plant fat and an amount of water less than 10 wt %. The caramel exhibits a chewy texture when consumed but is yet depositable. The caramel is thus advantageously used in a confection. In addition to the caramel, the confection may comprise a crisp component. Methods of making the confection are also provided.