An Apparatus and Method for Tempering Confectionary
The present invention relates to a method and apparatus for tempering confectionary and in particular, chocolate.
Some confectionary such as chocolate contains crystalline fat. Depending on the manner in which the confectionary is cooled, the crystalline fat can adopt various polymorphic forms in the solid confectionary. In order to produce confectionary having an acceptable texture and appearance, the size and distribution of the fat crystals throughout the confectionary must be controlled.
A method of achieving such control is known as tempering and involves cooling the confectionary in its liquid state while stirring continuously to produce seed crystals of fat distributed throughout the confectionary.
European Patent EP 406090 discloses a method of tempering chocolate that utilises a closed recirculation of heated air. The apparatus incorporates a central chamber containing a mass of melted chocolate surrounded by an outer wall that defines a cavity surrounding the chamber, through which cavity heated air is circulated. The heat is transferred through the wall of the chamber in order to heat/temper the mass of chocolate contained within the chamber.
An object of the present invention is to provide an improved method and apparatus for tempering compositions such as confectionary which include crystallisable fatty material.
The present invention provides a method of tempering a composition comprising crystallisable fatty material, the method comprising the steps of providing said composition in a plurality of individual packets, heating and subsequently cooling the composition in accordance with a predetermined thermal profile.
Preferably said predetermined thermal profile is selected to be suited to the particular composition to be tempered. Said predetermined thermal profile may be adjusted depending upon the mass of the composition to be tempered.
In one embodiment, said heating and cooling is achieved by convection.
Preferably, said heating comprises stabilizing said composition at a temperature prior to said cooling.
Preferably, the method comprises transferring said packets to one of at least one temperature-controlled chambers, the temperature of said at least one chamber being controlled in accordance with a temperature requirement of the composition of each packet to maintain the composition at a desired consistency.
Preferably, said composition comprises chocolate.
The present invention further comprises an apparatus for tempering a composition comprising crystallisable fatty material provided in a plurality of individual packets, the apparatus comprising: a rotatable drum having at least one chamber arranged to receive said packets, a temperature sensor operable to measure the temperature of said chamber, a convector operable to supply heated air to said chamber, and a controller operably connected to said sensor and said convector to control the temperature of said heated air in accordance with a thermal profile of said composition.
In one embodiment, said drum is partitioned to define a plurality of separate chambers, each chamber having a temperature sensor operable to measure the temperature of said chamber and separate heating means for controlling the temperature of air supplied to the chamber to control the temperature within said chamber in accordance with a predetermined thermal profile selected in accordance with a temperature requirement of the composition of each packet to be tempered in the chamber to maintain the composition at a desired consistency. Preferably said drum is partitioned to define a plurality of axially spaced chambers.
Preferably the or each chamber is provided with an access door permitting loading of the or each chamber with said individual packets and subsequent removal of the packets.
Preferably, said apparatus comprises a motor operably connected to said drum and controlled by said controller to selectively drive said drum in both directions.
Preferably, said rotatable drum is connected to said motor via a drive belt.
Preferably a fan is operably connected to said motor for supplying air to said at least one chamber.
Preferably, said drive belt includes a self-tensioning mechanism.
Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, in which :-
Fig. 1 is which is a schematic view of an apparatus for tempering confectionary in accordance with a first embodiment of the present invention; and
Fig. 2 is a schematic view of an apparatus for tempering confectionary in accordance with a second embodiment of the present invention.
Referring now to the figure 1 , the apparatus comprises a housing 10 having a rotatable drum 12 for receiving confectionary, and in particular, individual sachets or packets (not shown) of chocolate of specific pre-defined quantities. The quantity of chocolate in each packet may vary considerably, for example in the range of from 1 Og to 30Og or greater. A conventional quantity would be 20Og, although it will be appreciated that any other quantity could be provided.
In the preferred embodiment, the rotatable drum 12 is driven in both directions by a motor 14 via a drive belt 16 having a self-tensioning mechanism 18. However, it will be appreciated that any suitable means may be employed to rotate the drum 12, for example the use of gearing (not shown) between the motor 14 and the drum 12.
A controller 20 is provided to control each stage of the cycle, for example by controlling the temperature of the drum 12, the frequency of alteration of the direction of rotation and the duration of rotation.
The apparatus further comprises a fan 22 connected to a temperature-controlled heater element 24 for generating temperature-controlled air. Preferable, the fan is electric.
An inlet 26 connected to the housing 10 allows air generated by the fan 22 to be directly conveyed into the drum 12.
The apparatus further comprises a temperature sensor 28 for detecting the temperature of the air in the drum 12. Preferably, the sensor 28 is located on the drum such that air is conveyed into the drum 12 via the sensor 28.
Using known characteristics of a confectionary, a thermal profile of the melt/temper process for the confectionary can be determined. So, for a given weight of confectionary, the controller 20 can control the heating and cooling tempering process in accordance with the thermal profile to thereby control the consistency of the confectionary. Thus, in this manner, the consistency of the confectionary can be repeatedly and consistently produced.
For example, the confectionary could display a smooth fluid consistency suitable for pouring and coating or a thick clay-like extrudible consistency, which is quick setting and which can maintain its extruded shape when setting, without the use of a mould.
The method and apparatus of the present invention may be applicable to any confectionary type composition comprising crystallisable fatty materials, preferably having a total fat content of approximately 10 to 85 % by weight.
The following example relates to a method of tempering chocolate according to a preferred embodiment of the present invention using an apparatus such as described above. Typically, the chocolate comprises 5wt % non-fat cocoa solids, 22 wt % cocoa butter, 27 wt % milk solids, 45 wt % sugar, 0.6 wt % emulsifier and flavouring and 0.4 wt % water.
To facilitate control of the consistency of the chocolate to be tempered, the temperature of the composition is stabilized to around 1°C of a predetermined value, preferably derived from the thermal profile of the composition being processed. Preferably, the composition, when stabilized, contains no solid fat crystals, i.e. it is in a completely de-tempered state.
A plurality of individually sealed packets, each packet containing chocolate, are deposited in the drum 12.
The fan 22 is activated and temperature controlled air transfers heat to the rotating drum 12, causing the individual packets to pass through a uniform stream of directed air currents within the drum 12, thereby heating the chocolate.
Advantageously, any temperature difference between a first and second packet within the drum 12 is negligible as the heat is being transferred by means of convection, thereby providing even heating of the packets regardless of their location within the drum.
The solid chocolate is melted and the temperature of the air in the drum is stabilized, preferably, at around 45°C.
The temperature of the air in the drum 12 is then reduced and stabilized at approximately 280C, before being increased to stabilize the temperature of the chocolate at 34°C. The length of time allocated to the tempering process will vary depending on various factors, in particular the type of chocolate being tempered, but as an example could last for between 15 and 20 minutes.
Individual groups of packets comprising the tempered chocolate may be subsequently transferred to one or more of a plurality of further independent rotating chambers 240- A, 240-B5 240-C, 240-D. Each further chamber is temperature controlled and the allocation of the packets to the chambers is dependent on the temperature requirement of the tempered chocolate such that it maintains a desired consistency.
For example, plain chocolate suitable for extrusion with a clay-like consistency is typically allocated to a chamber having a temperature of approximately 250C; white chocolate having a thick pipable consistency is typically allocated to a chamber having a temperature of approximately 27°C; and milk chocolate having a smooth pourable consistency suitable for coating surfaces is typically allocated to a chamber having a temperature of approximately 300C.
In this way, the chocolate is provided in a form where it can be extruded in a controlled manner, retaining its shape on removal from the packet. Preferably, the chocolate is removed from the packet through an aperture cut in the packet.
Once removed, the chocolate rapidly solidifies to retain its form, or flows freely to fill any gaps or crevices as desired. In this way, a chocolate bar comprising a combination of chocolate types and a combination of consistencies can be formed. The chocolate bar may incorporate complex patterns or may form a picture, without the need for a mould.
A further embodiment of the present invention is illustrated in figure 2, where like reference numerals have been used to describe like components. In order to provide a more compact arrangement, the drum 12 is subdivided into three separate chambers A,B,C, by means of radial partitions. Each chamber A,B,C has an access door 40 to permit insertion and removal of the packets of chocolate therefrom.
As with the first embodiment, a motor 14 is arranged to rotate the drum 12 via a drive belt 16. The motor 14 also drives a fan 22 passing air from an inlet 26 into a common air passage extending along the central axis of the drum 12. Each chamber A,B,C of the drum is provided with its own temperature-controlled heater element 24 for controlling the temperature of the air within each chamber. As with the first embodiment, the temperature profile within each drum is controlled based upon the chocolate type, chocolate mass and desired consistency of the packets of chocolate to be tempered therein.
The invention is not limited to the embodiments described herein but can be amended or modified without departing from the scope of the present invention.