BR112019020646B1 - PROCESS TO REDUCE THE VISCOSITY OF FAT-BASED COMPOSITIONS - Google Patents

Abstract

The present invention relates to a process for decreasing the viscosity of an edible fat-based material by imparting specific work to the material comprising the steps of: (a) imparting specific work to the material using a means of application of energy (such as a mixer or extruder) operated by one or more control parameter(s), wherein the rate at which specific work is imparted to the material is determined by the one or more control parameter(s); (b) preventing the energy-applying means from imparting additional specific work to the fat-based edible material once the viscosity of the fat-based edible material reaches a target viscosity (preferably 2 to 6 Pa.s) , where the specific work rate imparted to the fat-based material is determined by setting and/or adjusting one or more of the control parameter(s) to satisfy the relationship determined in equation 1: lnóóó=0, 5919-0.4268 lnóó ó where ó denotes the ratio between the initial viscosity and the final viscosity of the material and ó denotes the ratio between theoretical and actual work imparted to the material. Apparatus and methods using this process are also described.

Description

[0001] The present invention relates to a process, apparatus and method for reducing the viscosity of a fat-based composition and compositions prepared thereby. The invention is particularly useful for replacing or at least significantly decreasing or otherwise optimizing the traditional conching of fat-based mixes, as carried out in the chocolate production process.

[0002] In the traditional manufacture of chocolate or chocolate-like compounds, finely ground powders are dispersed in a continuous fat phase. Dusts found in chocolate or chocolate-like compounds are traditionally sugar, cocoa solids and/or milk solids. These are mixed in different proportions together with cocoa butter and/or vegetable fats, milk fats and emulsifier(s) such as lecithin. Ordinary chocolate is obtained by mixing sugar, cocoa butter, optionally other fats and cocoa mass. Milk chocolate contains fat and non-fat milk solids as additional ingredients. White chocolate contains milk fat and non-fat milk solids, sugar and cocoa butter and/or vegetable fat without the addition of cocoa mass or cocoa powder. Chocolate compounds can also be produced using alternative fats instead of or in conjunction with natural cocoa butter. Such alternative fats fall into three main categories, which are cocoa butter equivalents (CME), cocoa butter substitutes (CBS, for "cocoa butter substitutes") and cocoa butter replacers (CBR, for "cocoa butter replacers") ). Detailed discussions of these different types of alternative fats can be found in a variety of sources, see for example Traitler, H. et al. Midi, Journal of the American Oil Chemists Society, 62(2), 417-21 (1985).

[0003] Like many foods, chocolate and chocolate compounds are non-Newtonian fluids whose viscosity varies depending on how fast the fluid is agitated or pumped. Chocolate is very thick when static but becomes increasingly fluid when shaken or pumped more quickly. Non-Newtonian flow can be represented by two parameters: yield strength (also called in the present invention as YV or flow) and plastic viscosity (also called in the present invention as PV). Plastic viscosity is the force required to maintain a constant flow of a chocolate mass and is typically measured in Pascal seconds (Pa.s). Yield strength is the force required to initiate movement in a chocolate mass and is typically measured in Pascals (kPa).

[0004] As used herein, unless the context clearly indicates otherwise, the term "viscosity" refers to plastic viscosity (PV) and PV is preferably measured according to ICA method 46 (2000) with the Servais method referred to here providing an alternative method for measuring PV.

[0005] In the traditional method of producing chocolate, the chocolate ingredients are mixed and ground in a refiner or mill for a time sufficient to reduce the particle size of the constituent solids to form a powdery mass (also called here chocolate flake ). In the process step known as conching, this powdered mass is agitated (concheada) in a generally open mixer (ladle), although partially closed or even closed ladles are also known. Meanwhile, in the ladle, the dough is heated to a temperature of 50°C to 110°C for a period of time ranging from a few hours to a few days, depending on the type of product and the equipment used. Once conching is complete, the resulting chocolate is normally tempered and then chilled for an appropriate amount of time.

[0006] The conching of the refined flakes is considered essential for the development of an acceptable texture in the final chocolate. Mixing in the shell creates shear to break down solid particle agglomerates that might otherwise adhere to each other due to pressure or water bridges. The mixture also coats these solid particles with fat and disperses the fat-coated particles evenly throughout the chocolate mass. Conching can additionally change the flavor of the dough and remove unwanted volatile compounds such as water or acetic acid through evaporation.

[0007] Although the ladle is very important in the chocolate production process, it is a very inefficient mixer, taking up to three days for the finest chocolate (one day being more typical for conventional chocolate) to reach the desired texture and quality . The conching step is therefore energy intensive and time consuming. To improve conching efficiency, high shear mixers have been developed to generate high shear flow in the mass through means such as rotating removal elements or paddles rotating along an interior surface of a large container. Even with the use of high shear, liquefying chocolate flakes takes time as a typical ladle has a surface size to volume ratio, which means that only a small amount of the chocolate mass can be sheared at one time. . Ladles capable of liquefying chocolate on an industrial scale (eg with a processing capacity of tons per hour) take up considerable factory space and the capital cost of ladles of industrial dimensions is very high.

[0008] Thus, although there are many well-known problems with current conching methods, conching is still seen as an irreplaceable step in chocolate production, although it is not well understood.

[0009] Current conching knowledge is described and summarized in standard reference works, the "Industrial Chocolate Manufacture and Use" (Beckett) being one of the most widely used. The currently available version of Beckett is the "4th edition", published in 2009. The parts of Beckett most relevant to conching are chapter 8 - "Flavor development in cocoa and chocolate" section 8.5, which focuses specifically on flavor development in shell); Chapter 9 "Conching" which explains in detail why conching is used in making chocolate; and Chapter 10 "Chocolate flow properties"; which describes the current understanding of the rheological properties of chocolate. These portions of Beckett's 4th edition are incorporated herein by reference as evidence of the current common general knowledge of one skilled in the art regarding conching.

[0010] Beckett acknowledges that conching is not well understood and, for example, in section 9.1.1. 'Flavor development' Beckett states: "...It is the job of conching to remove the most unpleasant of these flavors and still retain the most desirable ones. It is possible to 'over-conch' and produce a very smooth product. , the conching time will depend on the initial flavor intensity of the cocoa and the product in which it is being used..." Beckett goes on to state "...the actual physicochemical changes that occur, as described in Chapter 8, are very complicated and not fully understood. However, the purpose of conching is essentially the removal of undesirable flavors, the transfer of flavor components between ingredients and, in certain circumstances, the development of more desirable ones that match the final product...

[0011] Beckett's next section is "9.1.2 Optimization of Flow Property" which further teaches: "...In most chocolate production units conching is preceded by a roller refiner or a hammer mill. This equipment grinds the chocolate mass to produce a friable paste or powder. It is the function of conching to treat this paste or powder and transform it into a flowable liquid, which can be poured into a mold or over the center of the product..." and also "...The conching process is necessary to rub the fat over these surfaces so that the particles can flow between each other. Also, some of the particles form loosely connected clumps, perhaps due to the presence of moisture or sugar amorphous on the surface of sugar (Niediek, 1970). These particles also need to be decomposed by the mixing action of conching"

[0012] A 2007 review article by Afoakwa et al, "Factors influencing rheological and textural qualities in chocolate - a review", Trends in Food Sci & Tech 18, 2007, 290 to 298, concludes as follows (on page 297) : "The physical properties, rheological behavior and sensory perception of chocolate are largely influenced by its processing techniques, particle size distribution and ingredient composition. To improve chocolate texture, solid particle size distribution and Ingredient composition can be manipulated to modify physical properties, rheological behavior and sensory attributes. Several improvements have been made in recent years on chocolate quality using various processing strategies and ingredient composition. However, the use of size distribution particle size and ingredient composition as tools to modify the rheological behavior and sensory properties of chocolate still requires a greater understanding of the underlying principles and factors that affect changes in flow behavior. Therefore, the factors that determine the character of chocolate during and after its manufacture require a very in-depth investigation. Additional studies require the integration of sensory and instrumental analyzes of texture and flavor release and characterizations of the effects of tempering on the melting behavior of chocolate."

[0013] Another theoretical discussion of chocolate rheology is also presented in the 2004 article "Determination of chocolate viscosity", C. Servais, H. Ranc and I.D. Roberts, Journal of Texture Studies, 34, 467-497. Servais evaluates a Casson model for measuring chocolate viscosity in a factory and validates the accuracy of methods used to measure viscosity that are available in a typical chocolate factory. The method described in Servais is one of the preferred optional methods for measuring viscosity in the present invention (unless the context indicates another method) and in that regard, Servais is incorporated herein by reference. However, Servais also concludes that there is no general relationship between the elastic limit (YS) and the Plastic viscosity (PV) of chocolate and states that the relationships found in this article are "very specific to the actual chocolate process" (at the bottom of the page 492).

[0014] Another 2009 article describing the rheology of chocolate is the "Comparison of rheological models for determining dark chocolate viscosity" International Journal of Food Science and Technology, 44, 162 to 167, Emmanuel Ohene Afoakwa, Alistair Paterson, Mark Fowler & Joselio Vieira. This article describes the rheological parameters of chocolate that are important for the chocolate manufacturer, which are presented as: shear viscosity and elastic limit, both of which are stated to be directly influenced by the product's particle size distribution (PSD) and composition. The article teaches that other parameters should not be considered as important for chocolate rheology. Afoakwa does not suggest a way in which these parameters (or any others) could be used quantitatively to control viscosity during manufacturing. Instead, Afoakawa concludes (in column 2, page 166) that: "The complexity of behavior combined with the flowing nature of chocolate is often an issue when choosing a representation or equation to evaluate the rheological properties of chocolates. Considered points of sufficient data, the use of interpolation data is normally not a difficulty, but extrapolation should be avoided."

[0015] Thus, literature such as Beckett's illustrate a common and long-standing belief that chocolate rheology is complex and difficult to predict and show the general skepticism in the area that rheological models can have practical use in the industrial environment. Current common general knowledge teaches one skilled in the art that it is extremely challenging to accurately model the rheological changes that occur in a chocolate mass during conching.

[0016] Another factor believed to be important in achieving the desired viscosity in a chocolate conching process is moisture reduction. The literature teaches that the presence of moisture leads to significant particle aggregation and crosslinking due to water bridges, and forms a capillary suspension ( Koos E., Willenbacher N. Science 331 (6019) (2011) 897 to 900) . Capillary suspensions consist of suspensions of particles with a small amount of a secondary immiscible liquid (i.e. water) with the bulk liquid, i.e. the fat phase. Capillary suspensions are formed when the secondary liquid wets the particles more than the bulk phase, causing the particles to be connected by a concave water bridge, which induces capillary forces. Typically, the energy of attraction between such particles connected by capillary forces is many times greater than the thermal energy kT, and orders of magnitude greater than van der Waals and gravity forces (Koos E. Curr Opin. Colloid Interface Sci. 19(6)(2014) 575-684). The relationship between the capillary forces Fc and the elastic limit ay for particles of equal size in direct contact is given by

[0017] Therefore, the elastic limit ay of a capillary suspension depends on the particle radius α, the interfacial tension r between the liquids, the contact angle θ of the three phases and the number and volume of water bridges (Bossler F., Koos E. de Langmuir 32 (6) (2016) 1489-1501).

[0018] In a conventional ladle, the impact of capillary forces on the yield strength and viscosity of the chocolate is obtained by reducing the moisture content of the chocolate mass before or during conching. Thus, a typical moisture content of a powdered dough such as chocolate flakes before conching may be 1.5% by weight, which is reduced to 0.8% or less by weight after conching to obtain a typical PV of 2 to 6 Pa.s and an elastic limit of 4 to 10 Pa at 40°C (Ziegleder G, Balimann G, Mikle H, Zaki H. süsswaren (confectionery) numbers 3, 4 and 5, (2003)) . The perceived moisture tolerance of chocolate masses obtained from other processes, such as the crumbling process, may be slightly higher (moisture content being 1.2% or less by weight) but it is still believed that these products should have low humidity after processing.

[0019] The diffusion coefficient of water in a liquid hydrocarbon (such as fat) is extremely low, on the order of 10-9 m2s-1; thus, reducing the moisture content to an acceptable level requires extended mixing and heating time using a conventional batch ladle. Thin film evaporators for cocoa liquor (such as a column apparatus sold by Petzomat) were developed 30 years ago in an attempt to solve this perceived problem of the need to remove unwanted volatiles as well as water more quickly. The so-called "high efficiency" ladles were able to liquefy chocolate more quickly by reducing conching times from 6 to 24 hours compared to about 72 hours using older longitudinal ladles. Continuous shells with extrusion systems were also used to accelerate liquefaction. However, whether using conventional, high-efficiency or continuous shells, it is still considered necessary to reduce the moisture content of the chocolate mass as much as possible. Thus, to date, one skilled in the art is taught to obtain desired flow properties from a chocolate mass, the process having to reduce the moisture content to a low level, typically less than 0.8% by weight. It also results in the additional technical handicap that preparing liquefied chocolate with a high moisture content (especially for amounts of 1.3% or more by weight) would be very challenging and impractical and/or uneconomical, if not impossible.

[0020] Unless the context indicates otherwise, the terms "low moisture" or "low moisture" as used herein (especially when referring to known chocolate materials and/or to chocolate materials of and/or used in the present invention) denote that moisture (if present as the term optionally encompasses the absence of moisture) is optionally present in an amount usefully less than 1.2%, more usefully less than 1.1%, even more usefully less than 1.0%, and most usefully less than 0.9%, for example, less than 0.8% by weight of the total weight of said composition (as chocolate material). When the fat-based material is chocolate or compound prepared through a crumbling process, the term "low moisture" will generally denote that the material has a moisture content of not more than 1.2% by weight. For fat-based materials other than chocolate or compound (or chocolate or compound prepared by processes other than the crumbling process), the term "low moisture" will generally indicate that the material is even drier, having a moisture level of not more than 0.8% by weight. It will also be recognized that the mention of any quantity, content or level in the compositions described herein means that the terms "moisture" and "water" are used interchangeably herein.

[0021] Unless the context otherwise indicates, the term "high moisture" or "high moisture" as used herein (especially when referring to chocolate materials from and/or used in the present invention) , denotes that moisture is present in an amount suitably at least 1.3%, most suitably at least 1.5%, most suitably at least 1.8%, and most suitably at least 2.0%, for example at least 2.5% by weight of the total weight of said composition (such as a chocolate material).

[0022] It will also be recognized that the moisture levels mentioned herein are those present in a fat-based material immediately after it has been prepared (e.g. in a process of the invention) and do not refer to moisture levels in a material aged in which, for example, moisture can be absorbed from the environment in which the material was stored.

[0023] So, for these reasons, there is a common assumption in the art that conching needs to also be used as or in combination with a drying step at any stage before or during conching to achieve the required low moisture level. One skilled in the art learns that chocolate needs to have a low water content of not more than 0.8% by weight (not more than 1.2% by weight if using a crumbling process) before conching, so that the conching is efficient. For example in prior art methods there may be a separate step to dry the flake prior to conching; reduced pressure can be applied to a ladle to evaporate water from the pasta more quickly during conching and/or the pasta can be overworked in the open ladle to provide more time for more water to evaporate. All these drying steps are disadvantageous since, for example, they add time and/or complexity to the process.

[0024] Excessive work refers to mixing the dough in a ladle even after the target viscosity has been reached. In a manufacturing environment, it is very difficult to consistently and safely prevent chocolate mass from being overworked. During conching, to determine the viscosity of the chocolate mass, samples are periodically collected and analyzed offline. It can take several minutes for the analysis results to be communicated to the shell operator and action to be taken, with a typical 40 minute period before the analysis results can be returned to the operators and implemented. Thus, with off-line analytical methods, the dough will be overworked for many minutes, even assuming a sample was taken (at random) at the time the desired viscosity was achieved. For an industrial line with a processing capacity of many tons per hour, even with a few minutes of excessive work, the mass wastes energy and material in significant amounts. Increasing sampling frequency to determine viscosity will add cost and cannot eliminate delay completely; so with current conching methods overworking the chocolate mass is unavoidable.

[0025] Routine overworking of the chocolate mass will obviously waste energy, with the added disadvantage of adversely affecting other desired properties of the chocolate. For example, the texture of overworked chocolate can be undesirable, for example, if the particle size is too small due to overgrinding. The taste of overworked chocolate can also be undesirable.

[0026] Typically, conching is carried out in a generally open container, and the longer the dough spends being conched, the more volatile components will be released. Typically the degree of evaporation during conching is not well controlled and not all of the material that is removed consists of unwanted flavors such as acetic acid. Thus, by overworking the mass there is a greater chance of also removing a greater proportion of the volatiles that may otherwise impart the consumer's desired flavor notes to the chocolate. Due to the perceived need to dry the dough, it is difficult to control conching to achieve a desired flavor of the resulting liquid dough, as flavor issues are compromised due to this factor, among many others.

[0027] Various other methods to improve or replace conching have also been described in the patent literature.

[0028] Applicant's patent application WO2004-00028 describes a process for decreasing the viscosity of a blend of a refined powdered fat comprising solids and fat. The mass is subjected to a rate so that there is sufficient flow in an elongated direction to break down the clumps and deep interactions between solids and fat. This produces a pasty mass comprising fat-coated solids. However, there is little guidance in this document on how this device and process can be operated most efficiently.

[0029] EP 0603487 relates to a process for plastically extruding a fat-based confectionery material comprising feeding a fat-based confectionery material, typically chocolate, into an extruder cylinder and applying pressure of a piston to non-pourable substantially solid or semi-solid form material upstream of a flow constriction of a die, at a temperature at which the material is isothermally extruded. This process makes it possible to form chocolate by extrusion. The starting material is a fat-based confectionery material in a liquid, pasty or solid or semi-solid form, but is already composed of solids that are already coated with the fat. Therefore, it is already a chocolate product when it enters the extruder. Typically, this material is in the form of chocolate buttons. The process is a forming operation to provide a temporarily plastic end product from a solid material, but it is not an operation belonging to the chocolate production process "as such".

[0030] EP 0775446 also refers to the cold extrusion of chocolate where the starting material is already chocolate.

[0031] Document US 4679498 relates to a method and apparatus for the rapid preparation of a chocolate paste from a pasty mass of solids and cocoa butter. A refined slurry undergoes a dry conching treatment on a screw conveyor and is then liquefied as additives are proportionately incorporated according to the recipe. The dry conching stage comprises a first simple kneading step, then a second kneading step in which the shearing and rolling intensity is gradually increased. Conching takes place on a conveyor screw, in which the screw provides shear and rolling and then elongation flow at the exit of the conveyor belt. Shearing and rolling is energy intensive and requires complex and expensive extrusion equipment. The use of extrusion equipment makes the process less versatile, since to modify the final characteristics of the product (such as viscosity) the equipment needs to be significantly and costly modified (for example, screw parameters such as pitch, size and shape of the screw). blade all need to be modified).

[0032] Document US 4861615 describes the preparation of chocolate mixtures in twin screw extruders.

[0033] Document US 3663231 discloses a continuous shell used in traditional chocolate factories, the shell providing shear forces to the fat and solid mass during the dry and liquid phases.

[0034] Document US 4,191,786 describes a dry baking method for producing a powdered chocolate mass, where the mass is not liquefied.

[0035] None of these shells or replacements are satisfactory. Prior art chocolate liquefaction processes produce liquid chocolate of inconsistent viscosity that varies periodically to produce consecutively thick and thin masses. Such variability in viscosity makes the process less viable when the chocolate is further processed after conching in steps such as screening, tempering and/or molding, and will impact the quality of the final product.

[0036] As Beckett acknowledges, conching is poorly understood so that it is not possible for one skilled in the art to control the conch for best results. Any attempt to replace or supplement the shell must be viewed in this light. Conching is currently a compromise step without a good theoretical understanding, so it cannot be easily improved as attempts to do so will always be subject to trial and error, and modifications may still result in an inefficient process or device. The capital costs of replacing the large number of existing shells and their essential role in chocolate production also discourage the use of shell substitutes. For all their problems, shells are well known and they work (if inefficiently). The use of any shell replacement is subject to unknown risks that, during operation in a manufacturing environment, may not work in a safe and practical manner or any improvements in efficiency observed for a chocolate composition in the laboratory may not be practically obtainable. in a factory and/or with the wide variety of chocolate masses that need to be industrially processed.

[0037] One skilled in the art learns that chocolate mass has a complex rheology and thus there are many variables that need to be controlled to produce a chocolate product with the desired viscosity as well as flavor properties. Current processes generate huge wastes of energy, time and/or other resources (e.g. money or soil) and cannot be readily adjusted to handle unavoidable variations in the fat-based masses used in the process safely to produce a consistent product of the ideal way; and/or have poor flavor control of the resulting liquid mass.

[0038] There is still a need to provide a fast and energy-efficient process for reducing the viscosity of a fat-based mass (eg, when liquefying chocolate). There is also a need for a means to control the liquefaction process reliably so that the liquefied mass has consistent properties so that, for example, the process can be controlled to adjust for variations in the fat-based mass. It would also be desirable to provide an improved and controlled method for liquefying a chocolate flake to an ideal viscosity with reduced drying or no drying, for example, so that material with a moisture content above 0.8% by weight can be processed. There also remains a need to better integrate the liquefaction step of the process with other parts of chocolate production to provide improvements to the overall process that can be readily deployed industrially in a factory. It would also be desirable to operate conching or other liquefaction processes in a way where the flavor of the resulting liquid can be controlled more flexibly and/or with a wide variety of different masses. It is an object of the present invention (and different aspects and embodiments thereof) to solve some or all of the many different problems described herein.

[0039] Therefore, broadly in accordance with the invention, there is provided a process for imparting a specific job to an edible fat-based material to reduce the viscosity of the material until it reaches a predetermined target viscosity (qaivo), where the process comprises the steps of: (a) imparting a specific total amount of work ra to the fat-based edible material using an energy delivery means operated by one or more control parameters, both rate and the total amount of specific work imparted to the material is determined by one or more of the control parameters; and where the fat-based material flows through the energy application means at an instantaneous rate at a given moment in time 't' after the start of step (a) whose flow is denoted by Qt (b) controlling the means of application of energy means reaching a predetermined target viscosity (yaivo); wherein the rate of specific work done to the fat-based material is determined by controlling one or more of the control parameter(s) such that the specific work done by the means of energy application at a time t' after the start of step (a) satisfies the relationship determined in equation 1: where: (i) eta (nt) denotes the viscosity at time t' after the start of step (a) of the fat-based material measured as plastic viscosity according to the ICA 46 method (2000); (ii) omega (rat) denotes the total amount of specific work imparted to the fat-based material after time t' since the start of step (a) calculated from the power and flow rate as determined by equation (2): (2), where: Pt denotes the power (measured in kilowatts (kW)) conferred on the fat-based material by means of energy application at time t' after the start of step (a) Qt denotes the instantaneous flow rate (measured in kg per hour (kg/h)) of the fat-based material through the energy application means at time t' after the start of step (a); and (iii) A is from 0.5 to 0.7; and (iv) B is from 0.3 to 0.6. (c) preventing the energy application means after t = T from imparting specific work to the fat-based material, the time T being determined from equations (1) and (2) and the predetermined target viscosity (target n ).

[0040] T can be expressed in any suitable units.

[0041] As used herein the terms "means of applying energy" and "means of imparting energy" are synonymous and used interchangeably.

[0042] When equations (such as (1) and/or (2)) are generally referred to in the present invention, it will be understood that unless the context clearly indicates otherwise, this also covers all embodiments of such equations as those respectively designated as equations (1A) (1B) and/or (2A).

[0043] A preferred embodiment of a process of the present invention allows the total or partial elimination of inefficient use of ladles for the liquefaction of chocolate. Process conditions can be monitored so that the chocolate mass can be continuously mixed and subjected to suitable shear forces, for example, to convert flake into liquid chocolate mass optimally.

[0044] Usefully, the average (average) power applied during the duration of steps (a) and (b) is indicated as Pm which can most usefully be calculated from the instantaneous power measurement Pt used at several different times "t" and/or calculating the average of the total energy imparted over the total duration time "T" of step (a).

[0045] In one embodiment, the average and/or instantaneous power may preferably be a power of at most 100 kW (low mechanical energy), preferably less than 50 kW, and most preferably less than 15 kW. In one embodiment, the average and/or instantaneous power may preferably be a power greater than or equal to 2.5 kW, greater than or equal to 4.0 kW, such as between 2.5 kW and 100 kW .

[0046] Conveniently the average (average) flow rate (measured in kg per hour (kg/h)) of the fat-based material through the energy application means released during the duration of steps (a) and (b) is indicated as Qm, which can be most conveniently calculated from the instantaneous flow measurement Qt used at several different times "t"

[0047] In one embodiment, the average and/or instantaneous flow rate may preferably be between 90 and 6000 kg/h, preferably between 200 kg/h and 2000 kg/h, and more preferably between 500 kg/h and 1500 kg/hr.

[0048] Advantageously, the total amount of specific work that needs to be imparted to the fat-based material during steps (a) and (b) to obtain the predetermined target viscosity (paivo) is denoted by w and, more advantageously, ra can be calculated from equation (1A):

[0049] Usefully, the total specific work ra conferred on the fat-based material during steps (a) and (b) can also be determined by equation (2A):

[0050] Preferably, the time T (which is the duration over which the energy application means imparts specific work ra to the fat-based edible material in step (a)) can be determined from the Pm values and/or Qm alone and without any other factor.

[0051] In one embodiment of the invention, the duration (T) for step (a) is determined in advance before the start of step (a) by calculating a value for Pm or Qm corresponding to ra and ^aive and satisfying both equations (1A) and (2A) and more preferably these parameters Pm and Qm are both adjusted in parallel such that T is at a minimum (i.e. step (a) carried out in the shortest possible time to reach the viscosity -target (paivo)•

[0052] In another embodiment of the invention, one of Pm or Qm can be fixed and the other of these parameters can be adjusted using the control means during the operation of step (a) to reach that value of ra corresponding to ^ target calculated from equation (1A). This can make the calculation, operation and control of the energy application means simpler (for example, fewer sensors or control means can be used since only one of the mass flow or power to the energy application means energy are adjusted), but this may result in a duration (T) for step (a) that is not the shortest that could be achieved.

[0053] In yet another embodiment of the invention, if one of the parameters (for example, the power P, the flow Q or the time T) cannot be easily adjusted or controlled, then the other(s) can ) be adjusted instantaneously and/or over the duration of step (a) to satisfy any one of equations (1) and/or (2) in the present invention.

[0054] In the process of the present invention, as the material flows through the energy application means, it is preferred to have a residence time therein of one hour to 72 hours, more preferably 2 to 48 hours, most preferably from 5 to 30 hours, and most preferably from 10 to 24 hours.

[0055] Usefully, the residence time also corresponds to the time T for the duration of step (a) in which case it will be recognized that, to obtain a desired residence time, the average flow Qm will be defined to satisfy equation (1) and, optionally, equation (2), for example, by adjusting the average power Pm. However, if the required value for the average flow Qm is outside what is possible for a given device (e.g. certain restrictions on power and/or available flow), then it will be understood that this residence time cannot be achieved. by following the process of invention.

[0056] The process of the present invention may be a batch process, in which case it is preferred that the apparatus of the invention comprises a receptacle into which a batch of the fat-based mass to be liquefied in a process of the invention is added. It is also preferred that apparatus for use in a batch process of the invention have an outlet conduit fluidly connected to an outlet vessel that can hold the batch of liquid mass after processing. It is also preferred that apparatus for use in a batch process of the invention have an outlet conduit fluidly connected to an outlet vessel that can hold the batch of liquid mass after processing.

[0057] However, the process of the present invention in which the viscosity reduction is controlled according to the model described here also allows the possibility of a continuous or semi-batch process, since the process can reach a desired viscosity safely and predictable without overworking the edible dough. Thus, in a continuous process of the invention, the process can be operated such that, in step (a), the edible pasta is retained in the processing chamber for the shortest possible period necessary for the energy application means to impart the minimum energy necessary to achieve the required viscosity. In this way, the apparatus can be readily designed and the energy application means can be operated so that there is a continuous flow of mass through the apparatus.

[0058] Another preferred embodiment of the present invention provides a process for imparting specific work to a solid or semi-solid chocolate or compound mass to liquefy the mass to reduce the viscosity of the mass until it reaches a desired liquid viscosity, the process comprises the steps of: (a') imparting specific work to the dough using a mixer and/or extruder operated by one or more control parameter(s), the rate at which specific work is imparted to the dough is determined by one or more control parameter(s); (b') controlling the mixer and/or extruder to impart specific work to the dough until the viscosity of the dough reaches the desired liquid viscosity, where the rate of specific work imparted to the dough is determined by controlling one or more of ( s) control parameter(s) for the mixer, so that the specific work done by the mixer satisfies the relationship determined in Equation (1B) (i) eta (n) denotes a viscosity ratio calculated from: the initial dough viscosity just before step (a) indicated as eta0 (n0); and the target viscosity of the mass after liquefaction has been completed indicated as target (n target), the ratio being determined by equation (3B) where the eta0 (n0) and etatarget (ntarget) viscosities are both measured under standard conditions in the same method and same units (preferably at a temperature = 30°C in the Y method in units of Pa.s) (ii) omega (w ) denotes a specific work ratio calculated from: the specific theoretical work imparted to the dough after step (a) assuming the mixer operates at 100% efficiency is denoted as omegatheory( w theory); and the specific real work imparted to the dough after completion of the mixing step (a') is indicated as omegareal (wreal); the specific work ratio being determined by equation (4B): where the omegatheory (w theory) and omegareal (wactual) specific energies are both measured under standard conditions in the same method and in units of kWh per kilogram of material.

[0059] Usefully in the first embodiment of the invention: Vaivo is less than 6 Pas; and ^reai is greater than 61300 kWh/kg).

[0060] Conveniently in the first embodiment of the invention of the mixer in the mixing stage (a') the control parameters are defined and/or adjusted during mixing so that the mixer applies a continuous shear force to the mass to impart specific work w to the mass and reduce the viscosity n at a rate determined by Equation (1B).

[0061] Advantageously, the process of the first embodiment is operated in such a way that the average flow rate of the edible mass through the processing chamber of the invention is at least 1 kg per minute and, more advantageously, a maximum of 100 kg per minute. Even more advantageously, the average flow rate is from 10 to 80 kg per minute, and more advantageously from 20 to 70 kg per minute.

[0062] Useful control parameters are the temperature experienced by the edible mass inside the processing chamber (optionally controlled by operating suitable heating and/or cooling means); More useful control parameters are for a mixer: its mixer speed, power input and/or operating time; and/or for an extruder: screw speed, power input; and/or residence time of the material in the extruder.

[0063] The process of the invention controlled using the relationships described herein advantageously provides a means to optimize the power, flow and/or duration of step (a), more advantageously to optimize and/or minimize many factors of a process of the invention in addition to its duration, and, for example, all of these can have different and varied impacts on other factors such as cost. Some examples of these factors might include: total energy used; amount of liquefied material; time spent, total process cost and/or any combination thereof, for example, to find an optimal consensus on process operation when a plurality of such factors are considered together.

[0064] For example energy costs, operating costs and/or material costs vary over time or from place to place (and may even vary during the operation of the same process). As such, it is likely that the most cost-effective way to operate the process is not always fixed or consistent, even if the same process is operated on the same material, the same assets, and the same location. Thus, yet another embodiment of the present invention optionally provides an opportunity to optimize, reduce and/or adapt the costs of liquefaction of edible fat-based masses (such as chocolate) to the set of operational circumstances of a given place, time and/or or product to a greater extent than has been possible heretofore and which provides opportunities for new processes at cost savings compared to prior art conching processes and/or allows known existing conching processes to be operated in a manner more cost-effective than they are currently being.

[0065] If ^aivo corresponds to a liquid viscosity, then T will be the time taken to achieve liquefaction of the fat-based material.

[0066] The initial fat-based material that can be liquefied according to the method of the invention includes, more particularly, powder or pasty mixtures traditionally obtained after refining or grinding sugar solids and/or cocoa solids and/ or full fat milk solids in order to reduce the particle size of the solids in the mixture. The fat may include cocoa butter, chocolate substitutes containing direct cocoa butter replacements, stearins, coconut oil, palm oil, butter or any mixtures thereof. Solids can include cocoa solids, sugar, sugar alcohols, sugar substitutes, milk such as skim milk or whole milk powder, vegetable solids and any combination of these. After homogenization and refining, the fat-based starting material can result in flakes, powders or granules with particle size of different mass, more preferably with an average particle size, in particular, less than 50 microns, with more preferably even less than 30 microns, so that the final material is not gritty in the mouth. The proportion of fat may depend on the product to be liquefied.

[0067] In one embodiment of the process of the present invention additives such as emulsifiers can be added in small amounts at different stages (e.g. before and/or during conching) to help further reduce viscosity, e.g. lecithin, polyricinoleate polyglycerol (PGPR), ammonium phosphatide and/or others. However, in a preferred embodiment, such viscosity-reducing aids are not added and the viscosity is reduced by controlling only the means of applying energy. Such additives may affect other dough properties such as flavor and texture, or may be incompatible with other ingredients. It is an optional advantage of the present invention that the recipe for the fat-based material need not be changed during or for conching.

[0068] Optionally in one embodiment of the process of the present invention, the process proceeds in the absence of a separate moisture reduction step.

[0069] It is very surprising that, despite the alleged complexity in the rheology of fat-based doughs such as chocolate, the applicant has found that the simple predictive model of equation (1), which relates the amount of specific work imparted to a dough to the based on fat to viscosity, can be used to reliably and consistently predict dough viscosity during liquefaction to allow liquefaction to be achieved efficiently while minimizing or eliminating dough overwork. It was also found that the use of the model can, optionally, make it possible to operate a process for liquefying chocolate mass at much higher moisture levels than in previously typically liquefied masses and to produce liquid chocolate with a moisture content highest (>0.8% by weight).

[0070] In one embodiment of the invention, one can surprisingly provide fat-based liquid edible material with a high moisture content (e.g., from 1.3 to 5.0% by weight) as when the wetter material is liquefied according to the process of the invention, and low target viscosities can still be achieved (e.g. from 2 to 6 Pa.s) in a reasonable amount of time (e.g., depending on the material, from 6 to 24 hours) . This is comparable to viscosities obtained by conching for a similar period of much drier (moisture content 0.8% or less) but otherwise similar fat-based edible material. From common general knowledge, it is not expected that a fat-based material with a high moisture content can be shelled to provide adequate viscosity reduction at all or in a reasonable amount of time.

[0071] In a useful embodiment, the process of the invention can be used to liquefy fat-based materials by controlling only the apparatus as the means of applying energy (e.g., adjusting the speed and/or power of a mixer) in response to a measured viscosity. The ingredients used to prepare the fat-based material can thus optionally remain unchanged (constant initial recipe) and additional additives (such as emulsifiers) need not be added to the material during the process to achieve or accelerate liquefaction of the fat-based material. Components of the fat-based material may still be lost during liquefaction (e.g. by evaporation) so that the composition of the final product may differ from the composition at the start of the process, but preferably by controlling the means of application of energy, it is not necessary to add other ingredients solely for the purpose of aiding liquefaction.

[0072] The model determined by equation (1) in the process of the invention can be used to predict and control the viscosity at any point or at multiple points or continuously during the execution of steps (a) and/or (b) as the viscosity is reduced to reach the target viscosity. Preferred target viscosities for chocolate are in the range of 2 to 6 Pa.s.

[0073] For example, the control parameters can be used to control the operation of the energy application so that ra represents the desired target viscosity for the liquid chocolate mass and, in this way, the process will interrupt the means of application of energy promptly and avoid or reduce the excessive work of the fat-based material. Alternatively or additionally, the control parameters can be used to control the operation of the energy application means so that ra represents one or more intermediate viscosities between that of the starting material before step (a) and the target viscosity (where the intermediate viscosities will be higher than the target) in which case the process is operated so that the ratio determined by equation (1) is maintained as much as possible throughout the process (subject to the rate at which viscosity measurements are taken). If the measurement and generation of control parameters are substantially continuous then, preferably, equation (1) will be satisfied throughout the operation of steps (a) and (b) of the process. Without being bound by any theory, continuous monitoring and feedback is believed to be advantageous, as following equation (1) at all times reduces the viscosity of the fat-based material in the most energy and/or time efficient manner. .

[0074] The actions of checking work in step (a) and controlling the means of applying energy in step (b) can be simultaneous (for example, as part of a feedback circuit where (a) and (b) are the same step) which is preferred, and more preferably the control parameters are generated frequently (most preferably continuously) so that the energy application means perform optimally throughout the process. However, in a less preferred embodiment steps (a) and (b) may also be sequential, with step (a) being performed and then optionally paused or interrupted (e.g. to allow time for an off-site analysis or measurement). of line) and then control of the power application means is carried out in step (b) and then, if necessary, step (a) is restarted. In this embodiment, steps (a) and then a (b) can be repeated as many times as necessary until the desired target viscosity for the fat-based material is achieved gradually rather than continuously.

[0075] Control of the energy application means can be achieved in different ways. For example, in one embodiment of the invention step (b) uses one or more detection means optionally combined with one or more control means.

[0076] The detection means may comprise sensors that measure input parameters that can be used directly and/or indirectly to determine: the viscosity of the fat-based edible material and the specific and/or theoretical work released by the application means of energy to fat-based material.

[0077] The input parameters can be measured from the fat-based material, the energy application means, the related apparatus used in the process of the invention and/or the environment in which the apparatus is used (e.g. temperature environment and/or pressure). The input parameter(s) alone or in combination with other parameters can then be used directly or indirectly to calculate and/or determine one or more other parameters and/or properties that are useful and/or or used in the process of the present invention, such as those selected from the group consisting of: omegatheory theoretical work (w theory); work in time "t" omegat (wt); target viscosity etaaive (target); initial viscosity etao (n0); and/or viscosity at time "t" etat (n t).

[0078] The control means can operate on the energy application means using control parameters derived directly and/or indirectly from the input parameters (for example parameters calculated from the input parameters) in real time or at intervals pre-selected time periods (eg when input parameters are sampled) during the process of the invention.

[0079] The means of applying energy can be controlled during step (b) (and optionally step (a) when these steps are simultaneous) in response to changes in input parameters in a way that equation (1) will be satisfied.

[0080] In a preferred embodiment of the process of the invention, the response of the control means (which operate to control the energy application means) to changes in input parameters can be immediate and instantaneous if the control means and detection means are in constant contact, so that equation (1) will be satisfied.

[0081] In another embodiment of the process of the present invention, the response to such changes in input parameters can be delayed or delayed if the control means and the detection means are in contact only intermittently (for example at predetermined intervals during the process or with the use of batch sampling and material analysis), in which case, although equation (1) will generally be satisfied at the end of the process, at any point during the process it will be understood that it is possible that the viscosity and work parameters deviate from the ideal values determined by equation (1) before they can be restored to a range governed by equation (1) through the means of control. The shorter the interval between when data or samples are taken, the less likely it is that the fat-based material will deviate from the desired range of parameters and the more advantageous the overall process control (e.g., achieving more energy efficiency or cost savings, etc.).

[0082] It is also possible that the detection means indicate that there is an initial analysis of the fat-based material and/or energy application means, and this initial analysis is used to also adjust the control means (a) to an initial configuration such that the energy application means then operate according to these configurations throughout the process unchanged to achieve a reduction in viscosity, in accordance with the relationships determined in equation (1) in the present invention.

[0083] The sensors can measure input parameters in real time or at preselected time intervals during the process of the invention. The sensors may comprise physical devices situated on or with the equipment used to carry out the process of the invention, preferably the control taking place in real time. Preferably, the sensors are situated as close as possible to the energy application means (e.g. in a processing chamber where the energy application means work the fat-based material) so that the data is as accurate as possible. as possible and/or minimize errors due to extraneous factors such as energy losses, etc.).

[0084] Means of detection may also encompass the process in which representative samples of the fat-based edible material are collected at different times during the process, in which the samples are analyzed separately and the results are then manually fed back into the process of the invention. This quantized material sampling process may be more suitable for a batch-type process in which steps (a) and (b) are not simultaneous and step (a) of the process is interrupted and restarted after adjusting the media configuration of energy application.

[0085] In another embodiment of the invention, steps (a) and (b) comprise an automatic feedback circuit in which the instantaneous amount of work applied to the fat-based material by the energy application means is controlled through a means control, the control means being in direct or indirect connection with the sensing means so that the control parameters are generated directly and/or indirectly in response to changes in the input parameters so that equation (1) is satisfied.

[0086] As used here, "A" is a constant related to viscosity (Pa.s). Without being bound by any theory, it is believed that when the specific work tends to 1.0 (ra ^ 1.0) then "B" can represent a dimensionless constant related to the reduction of the rate of viscosity per applied specific work (Ln n / Ln ra).

[0087] The constant indicated in the present invention as "A" is from 0.5 to 0.7, preferably from 0.55 to 0.65, more preferably from 0.57 to 0.61, even more preferably from 0.580 to 0.605, and most preferably from 0.5900 to 0.6000, for example from 0.592 to 3 significant figures, such as from 0.5919 to 4 significant figures.

[0088] The constant indicated in the present invention as "B" is from 0.3 to 0.6, preferably from 0.35 to 0.55, more preferably from 0.37 to 0.50, even more preferably from 0.410 to 0.440, and most preferably from 0.4200 to 0.4300, for example from 0.427 to 3 significant figures, such as from 0.4268 to 4 significant figures.

[0089] The relationship shown in equation (1) is considered valid over a wide range of fat-based doughs having different compositions and, as such, it provides an effective means for optimal control of a process for liquefying fat-based doughs fat, for example, defining the work required to generate a viscosity during the liquefaction process. The process parameters that need to be controlled can be defined prior to liquefaction, for example by presetting a constant or pre-programmed varied mixer speed that is predetermined from equation (1) to release that specific job that will achieve a given final viscosity in the product at a given time. Monitoring can also be real-time with feedback to control the means of energy application (e.g. control of mixer speed or extrusion speed) to ensure that these parameters remain within this ideal relationship - i.e. the work The specific amount added at any time during the process can be adjusted in real time to match the measured instantaneous viscosity of the output mass so that equation (1) is satisfied. In one embodiment, process control as described herein ensures that the minimum amount of energy required to liquefy the mass is used.

[0090] This model described here (in equations (1) and/or (2) also provides a means to select, design and/or use devices to liquefy fat-based masses, such as chocolate, which may be more efficient than traditional ladles. It also provides a means to improve the operation of known ladles and/or other fat-liquefying devices to avoid overworking the fat-based mass. The process can be stopped once a desired viscosity is achieved and/or at any point in the process the energy input will be equalized so that the optimal amount of energy is added to reduce the chances of instantly overworking the fat.Using the model described here, this can be predicted in advance with ease by measuring added work.

[0091] In another embodiment, the measurement or calculation of a parameter - specific work added to the fat-based mass (which can be further determined from simple parameters in a mixing step such as time and shear rate of a mixer and/or the power input to the mixer) - can be used to determine (and thus control) when a given target viscosity is reached. At that point further liquefaction can be avoided (eg with interruption of ladle or other mixer). This avoids the need for complex viscosity measurement that can be difficult to perform in real time. This allows for the possibility that the liquefaction of a fat-based mass could be a batch, semi-batch or continuous process. In a semi-batch process, each batch can be generated automatically after the previous one. In a continuous process, energy can be applied to the dough in an energy application zone through which the dough moves at the correct speed to satisfy equation (1) to continuously generate a resultant product that consistently has the generated target viscosity. in the most energy-efficient way possible.

[0092] In yet another embodiment of the process, the invention additionally or alternatively also allows the process to be operated in the most efficient manner possible in terms of time, i.e. the process can be operated to provide the desired total specific work to the fat-based mass at a rate to reach the target viscosity in the shortest amount of time (or a target). It will be understood that imparting a higher specific energy to a fat mass at a given time will initially require a higher potency of the energy delivery means. However, as potency increases, the means of energy application may impart energy to mass with decreasing efficiency (i.e., a higher percentage of total potency may be lost to the environment and not imparted to fat mass). Thus, there will be a limit where a further increase in the total power of the means of energy application will not impart additional energy to the mass due to these efficiency losses, i.e. there will be a minimum time required to reach any target viscosity regardless of the means of application of energy used and power. However, the model of the invention will allow this theoretical minimum time to be calculated and the process to be operated in order to obtain this shortest possible time (or as close as possible to it, considering other limiting factors).

[0093] In yet another embodiment of the process, the invention also allows, additionally or alternatively, for the liquefaction process to be operated with its parameters defined and/or adjusted to operate in the most cost-efficient manner, that is, that the process can be operated to deliver the desired total specific work to the fat-based mass at a rate to reach the target viscosity in the most cost-efficient manner (or compatible with a target cost) considered as the cost of the liquefaction alone and/or as part of an overall cost of a multi-step process of which liquefaction forms part. It will be recognized that the cost is a function of many different variables such as the cost of energy supplied to the energy application means, the cost of raw materials and/or the cost of processing capacity (related to the cost per unit time to operate the process), among other parameters. The model of the present invention provides a tool that is optionally combined with other models and known mathematical tools (such as statistical models, finite element analysis and/or neural networks) with other parts of the process that can be used to minimize the total cost of operation. of the process of the present invention. The cost may vary according to fluctuations in variables which, in some cases, may occur in real time. Typically, however, the process of the invention would be optimized to operate at minimal cost for each operation or batch campaign where the chocolate is liquefied, as parameters affecting cost are less likely to change frequently or in real time.

[0094] To generate the control parameters used in step (b) to control and/or adjust the means of energy application in step (a), any suitable mathematical process model can be used in conjunction with equation (1) (and, optionally, equations (2) and/or (3) and/or (4) in the present invention) and/or the input parameters of the present invention. Such models may, optionally, be calculated or generated by a computer and may include suitable mathematical techniques or models, such as: neural networks, statistical models and/or finite element models that predict, in whole or in part, one or more of the parameters of control. These mathematical models can be used in conjunction with advanced controllers, software and/or algorithms to calculate and/or predict optimal settings for the control means used in the process of the present invention. In this way, one or more control parameters, which are used to operate the control means, may be partly or wholly derived from empirical data (e.g. with the use of one or more input parameters from the sensing means) and partially or fully predicted by mathematical models (eg where control parameters are predicted from theory). Models may or may not be adjusted in light of experience (called adaptive or learning models such as neural networks, where input parameters are fed into the model to generate a revised and improved model for further use, the steps being iterative and/or repeated). The templates can be used separately from the apparatus of the invention to generate control parameters in a process of the invention which are manually fed or entered into the control means (e.g. by a human operator) or the templates can be integrated into the control means and and/or to the detection means of the apparatus of the invention so that the control means (and therefore the energy application means) are operated automatically and substantially without any human intervention.

[0095] In the present invention, the energy imparted to the material is to a first approximation presumed to be equal to or at least 90% equal to the energy output of the energy application means (such as a mixer).

[0096] Preferably reducing the viscosity of an edible fat-based material where in step (a) the work application means comprises a mixing step using a mixing means wherein the mixing rate is controlled by a or more of the control parameters.

[0097] Optionally, the viscosity of the fat-based edible material is reduced until reaching a target viscosity of 2 to 6 Pa.s and/or an elastic limit of 4 to 10 Pa.

[0098] The viscosity of the edible fat-based material of the invention and/or produced according to the process of the invention can be reduced without the need for a moisture reduction step before, during and/or after steps (a) and/or (b) the process of the invention.

[0099] The work application means can be advantageously controlled by defining and/or adjusting one or more control parameters to ensure that the specific work rate given to the fat-based material satisfies equation (1) during step (The).

[0100] More usefully, the energy application means are controlled by initially calculating the specific work rate using equation (1) and defining one or more control parameters, so that the initial rate of the means energy input remains substantially constant throughout step (a).

[0101] Conveniently, the specific work rate given to the fat-based material and/or the viscosity of the fat-based material are monitored during step (a) and these values are fed to an automatic control means so that one or more of the control parameters are adjusted to operate the energy application means to ensure that the specific work rate imparted to the fat-based material satisfies equation (1) throughout step (a).

[0102] The control means described herein may comprise one or more sensors and/or control units operated by a computer.

[0103] The energy application means (such as a mixer or extruder) can be controlled by one or more control parameters generated by one or more models using equation (1) (and/or equations (2), ( 3) and/or (4) in the present invention) to indirectly or directly calculate the control parameters.

[0104] Preferably, in the process of the invention, the fat-based edible material is a fat-based confectionery material, more preferably a chocolate material, and most preferably chocolate mass or compound mass.

[0105] The process of the invention can also be operated so that the control parameters are defined and/or adjusted using equation (1) to optimize another property as one or more selected from: energy efficiency of the process; time spent by the process, processing capacity of the material throughout the process; and/or cost of operating the process.

[0106] In a further aspect, the invention broadly provides an apparatus suitable for use in a process of the present invention, the apparatus comprising: i) optionally a container suitable for receiving an edible fat-based material; ii) an inlet conduit optionally in fluid connection with the receptacle, where present, the conduit being suitable for conveying the fat-based material to a processing chamber; iii) a processing chamber comprising an energy application means, the energy application means capable of imparting specific work to the fat-based edible material within the chamber to reduce the viscosity of the material; iv) optionally an outlet conduit in fluid connection with the processing chamber, so that material of reduced viscosity can be conveyed through the outlet conduit to be collected for subsequent use and/or to another apparatus for further processing; wherein: A) the input conduit and/or the processing chamber (and, optionally, the receptacle, when present) comprises one or more sensors that measure input parameters, the input parameters being capable of directly determining and /or indirectly: the viscosity of the fat-based edible material; and/or the specific and/or theoretical work released by means of applying energy to the fat-based material; and B) the energy application means is controllable by the control means operated by control parameters in a feedback loop to control the instantaneous amount of work delivered to the fat-based material, the control means and the means sensing devices are in direct or indirect connection, so that control parameters can be generated directly and/or indirectly in response to changes in input parameters to satisfy equation (1).

[0107] The apparatus of the invention for use in a continuous process may not require a receptacle (which is optional). The apparatus may be situated in-line as part of a continuous edible pasta process having pre- and post-processing steps. For example, the edible mass can be conveyed (e.g. by pumping) directly and continuously from another apparatus to flow through the inlet conduit and processing chamber, and then the reduced viscosity mass can be conveyed with the use of the output conduit directly to another device.

[0108] In another, more preferred embodiment, the inlet conduit and the processing chamber are the same (ie, the mass is added directly to the processing chamber).

[0109] The residence time and/or the mass flow in the inlet conduit and/or in the processing chambers may comprise (directly or indirectly) one or more of the control parameters that are optionally adjusted together with other control parameters with the use of the model described herein in such a way that the desired dough viscosity is achieved in a safe and predictable manner as the dough is continuously passed through the apparatus. Other control parameters useful for use in a continuous process of the present invention comprise the path length of dough and/or volume of dough as it travels through the processing chamber, while the means of applying energy impart specific energy to it.

[0110] The path lengths and volumes can be adjusted by mechanical means (for example, by adjusting the actual length of the conduit and/or diameter and/or volume of the chamber (for example, sliding walls and telescopic adjustment of the length of the tube, use of adjustable bellows and the like.) Alternatively, inert food-safe material may be added to or removed from the apparatus to slow down or speed up the flow of material therethrough.

[0111] A further preferred embodiment of the present invention provides an apparatus suitable for use in a process of the present invention, the apparatus comprising: i) a container suitable for receiving a solid or semi-solid chocolate or compound mass; ii) an inlet conduit in fluid connection with the receptacle, the conduit being suitable for conveying the solid or semi-solid chocolate or compounding mass to a processing chamber; iii) a processing chamber comprising a mixer and/or extruder capable of imparting specific work to the solid or semi-solid chocolate or compound mass within the chamber to reduce the viscosity of the mass until it is liquid and has the target viscosity; iv) an outlet conduit in fluid connection with the processing chamber, so that the liquid chocolate or compound can be conveyed through the outlet conduit to be collected for subsequent use and/or to another apparatus for further processing; wherein: A) the processing chamber comprises one or more sensors that measure input parameters, the input parameters being capable of directly and/or indirectly determining: the viscosity of the chocolate or compound mass; and/or the specific and/or theoretical work released by the mixer and/or extruder to the mass; and B) the mixer and/or extruder is controlled by control means operated by control parameters in a feedback loop to control the instantaneous amount of work delivered to the chocolate or compound mass, the control means and means of detection are in direct or indirect connection, so that the control parameters can be generated directly and/or indirectly in response to changes in the parameters so that equation (1) (and, optionally (2)) in the process of the invention be satisfied.

[0112] The means of applying energy used in the present invention may be a conventional mixer operated as described herein or may be any other device (such as an extruder) that can apply sufficient energy to the dough to satisfy equation (1). Suitable mixers may be an in-line mixer such as a pin mixer or a batch mixer such as a ladle or colloidal mill. In the process of the invention, the reaction of flavors that are normally created during conching can also be obtained through other more efficient methods such as the production of a chocolate crumb which is a pre-treatment that consists of producing an intermediate product useful in the production of products. of milk chocolate to prevent rancidity and provide special milk flavors for these products. Such methods are described, for example, in EP0940085. Other possible treatments for flavor development are reaction processes such as the combined milk powder and liquid process in a column commercially available from companies such as Petzomat. Removal of unwanted volatiles can also be performed more efficiently than conching by treating the cocoa mass, such as by passing the chocolate mass through thin stripping columns as described in Beckett. Furthermore, for some products, such as white chocolate or compounds produced from cocoa powder, flavor reactions and flavor removal only play a small role and therefore do not require additional flavor-related treatments.

[0113] Preferred energy application means for use in the apparatus and/or process of the invention comprise one or more devices (such as mixer(s) and/or extruder(s)) capable of applying high shear (e.g. > 200,000 s- 1) to the fat-based material, such a device is also referred to here as high shear devices (e.g. high shear mixers and/or high shear extruders). Advantageously, high shear devices can be controlled as described herein in the process of the invention to deliver to the fat-based material a shear greater than or equal to 200,000 reciprocal seconds.

[0114] All values described here as potential parameters for operation of the process of the invention are still subject to control in a process of the invention to satisfy equations (1) and/or (2) and if there is any conflict between the values below and the values determined by these equations, the latter shall prevail.

[0115] As used herein, the term high shear usefully denotes the application of shear forces to a material such that the minimum shear imparted to the material is greater than or equal to 200,000 reciprocal seconds. A more useful degree of high shear may be that used in conching and/or equivalent process steps, such as a shear from 200,000s-1 to 1,000,000s-1, with even more benefit from 300,000s-1 to 800,000s-1 , with the maximum benefit from 400,000s-1 to 600,000s-1.

[0116] The total amount of mechanical energy imparted to a material in the process of the invention (for example when the energy application means is a high shear mixer) may be greater than 100 kJ, preferably > 150 kJ, most preferably > 200 kJ, most preferably > 250 kJ, based on a material flow rate through the mixer of 50 kg per minute. Typically, the flow rate of fat-based material through a high shear mixer can be 1.5 to 100 kg per minute. However, in accordance with the present invention, the amounts of energy supplied to the energy application means will be suitably adjusted for a given flow rate and energy efficiency so that the total energy imparted to the material is consistent with equation (1).

[0117] Optionally, the degree of work that can be provided in steps (a) and (b) of the invention is carried out by operating energy application means (such as a high shear mixer) at a power greater than 100 kW ( high mechanical power), preferably > 150 kW, more preferably > 200 kW per kilogram of material, provided these values are consistent with equation (1).

[0118] In one embodiment of the apparatus of the invention, the energy application means may comprise a high shear mixer comprising a rotary drive shaft with paddles or the like deposited thereon to achieve mixing, to release substantially high shear amounts to fat-based material. Provided it is also compatible with equation (1) in this embodiment, the high shear mixer used in the process of the invention preferably can be operated at a rotational speed of 300 rpm or more, more preferably > 400 rpm, more preferably still > 500 rom, and with maximum preference > 600 rpm. Advantageously in the process of the present invention, the impeller in such a high shear mixer is operated at a rotational speed of 300 to 1000 rpm, more preferably 400 to 800 rpm, most preferably 400 to 700 rpm, and with the maximum preference of 500 to 600 rpm, provided that such values are compatible with equation (1).

[0119] Alternatively, the power application means may be operated at a rotational speed greater than 50 rpm, more preferably > 75 rpm, for example > 100 rpm, or > 200 rpm. Advantageously in the process of the present invention, the impeller in such a high shear mixer is operated at a rotational speed of from 50 to 400 rpm, more preferably from 75 to 350 rpm, for example from 75 to 275 rpm, or from 100 to 300 rpm, provided that such values are compatible with equation (1).

[0120] Suitable mixers that can be used as the means of applying energy in the present invention are described in Beckett (see section 9.2.3 for example) and can be any equipment known in the art that can apply one or both of the different types of mixing described herein: (i) shear mixing, where the chocolate is between two surfaces moving relative to each other; and/or (ii) elongational mixing, in which the material is pressed through or spread over a surface. Some non-limiting examples of equipment suitable for making such a mixture that are suitable for use in the present invention are described in section 9.4 of Beckett (which section is incorporated herein by reference, especially the Figures shown in that section). The energy application means used in the invention may preferably be selected from the group consisting of: batch ladles; horizontally agitated rotating shells (such as the Clover shell from Carle-Montanari; model PIV-HLC shell from Petzholdt) vertically agitated rotating shells (such as the Thouet RDC shell commercially available from Thouet KG Maschinenbau and/or the Frisse shell commercially available from Thouet Richard Frisse GmbH); high-speed mixers such as ladles (such as the one produced by Johansson Mischtechnik of Germany); single drive shaft shells (such as the Frisse ELK shell commercially available from Bühler); continuous shells (such as those using the continuous Thouet process available commercially from Tourell Conche Manufacturing Company and/or those using the continuous Frisse process); continuous shells with short residence time; continuous HCC shells (such as those in the HCC range available from Petzholdt Heidenauer); mass and/or cocoa liquor treatment devices (such as those using any Petzomat treatment (such as the Petzomat mass roasting system and/or the STC Petzomat treatment; the Convap treatment and/or the Carle-Montanari process; blenders ( such as the Pezholdt short-term high-density PIV 4000 shell; and/or the Petzholdt PIV intensive care unit); in-line high shear devices (such as those commercially available from Lipp Mischtechnik and/or the shell commercially available from Carle-Montanari Homega; and/or equipment commercially available from Lehmann that couples in-line blenders with ball mills); combined grinding and conching machines; ball mill recirculation systems (such as those using any of: the Lehmann continuous process; the Wiener chocolate plant and/or the Macintyre system (such as the Low & Duff Macintyre refiner/ladle); any of the equipment commercially available under any of the trade names and/or vendors contained in the following list (for example, as used in Examples 1 to 4 of the present invention): twin screw conveyor mixer (optionally 5 inch diameter commercially available from Readco); and/or any suitable combinations and/or mixtures thereof and/or their parts and/or components thereof.

[0121] None of the prior art mixers cited herein describe or suggest optimal operating conditions under which mixers can be used, operated and/or controlled that would be relevant to the present invention or that could overcome the technical drawback described above. For example, there is no teaching in any of these documents that could directly or indirectly lead a person skilled in the art to understand that chocolate can be liquefied by controlling the specific parameters presented here in the specific way described here.

[0122] Yet another aspect of the present invention provides a control device suitable for use in conjunction with at least one of: a process of the present invention; an apparatus of the present invention: and/or an apparatus capable of being used in at least one step of a process of the present invention; wherein the control device comprises at least one unit separate and/or separable from the apparatus of and/or used with the process of the invention; the apparatus comprising: at least one means for applying energy to impart a specific amount of work to an edible fat-based material to reduce the viscosity of the edible fat-based material; and at least one sensor means associated with the apparatus for generating at least one input parameter therefrom; wherein the control means comprises: at least one input interface capable of being connected with the at least one sensor means to receive at least one input parameter therefrom; and at least one output interface capable of being connected with the at least one power application means for sending at least one control parameter thereto; wherein during operation of the process of the invention; and/or apparatus of and/or used in the invention, wherein the control means is capable of: receiving via the at least one input interface the at least one input parameter of the at least one sensor means; with the use of at least one input parameter and equation (1) to calculate the at least one control parameter; and transmitting the at least one control parameter through the at least one output interface to the at least one power application means for controlling the at least one power application means to satisfy equation (1).

[0123] In one embodiment of the control device of the invention, the input and/or output interfaces may comprise a physical connection between the control device and one or more of the respective sensing means and/or energy application means, for example , through direct mechanical connections and/or electrical cables to them.

[0124] In another embodiment of the control device of the invention, the input and/or output interfaces may comprise a remote connection (for example wireless, infrared and/or internet-based interface) where there is no physical connection between the control device and one or more of the respective sensor means and/or energy application means.

[0125] In a preferred embodiment of the control device of the invention, the control device is a single unit (for example, kept in a box) that can be wired to the device and/or can be a remote control for the device . The control device can optionally comprise the at least one of the sensors that can be associated with the method of the invention and/or the apparatus of and/or used in the invention. Alternatively, the control device of the invention may be sensorless and connect (via the at least one input interface) to sensors that are already present in and/or associated with the apparatus of and/or used in the invention. Advantageously, the control device of the invention may comprise solid state hardware (such as integrated circuits and/or microprocessors) having algorithms integral thereto (such as hardware, software and/or firmware) so that the control unit can operate as required. described here by receiving at least one input parameter and transmitting at least one suitable control parameter.

[0126] Yet another aspect of the present invention features the use of a control device for the purpose of controlling viscosity in a process of the present invention. Preferably, control devices of the invention are used in conjunction with an apparatus of the invention. However, alternatively or additionally, the control devices of the invention can be used in conjunction with an apparatus suitable for use in a process of the present invention, which may be already known (such as a traditional ladle or similar), and more preferably, the control device can then be used to operate and/or control such known apparatus in a more ideal manner than previously realized.

[0127] Yet another aspect of the present invention provides a method for modifying an apparatus comprising an energy application means capable of reducing the viscosity of an edible fat-based material, the method comprising the steps of: a) providing a control device of the invention; b) optionally adding sensor means to the apparatus; c) associating the control device to operate the energy application means according to equation (1) during a process for reducing the viscosity of an edible fat-based material.

[0128] Preferably in step (c) of the method, said process is a process of the present invention.

[0129] Usefully in step (c) of the method, the process uses input parameters from the sensing means to generate control parameters for the energy application means.

[0130] Conveniently after the modification according to the method of the invention, the apparatus comprises an apparatus of the invention, most conveniently this is due to the modification for example where the apparatus before the modification is a conventional ladle.

[0131] Alternatively, the apparatus prior to modification already comprises an apparatus of the invention already suitable for use in a process of the invention, in which case the method is used to provide improvements to the apparatus of the invention, for example by providing improved capacity and/or or ease of use to the process of the invention.

[0132] In another embodiment, the apparatus and/or method of the invention may comprise and/or use (for example as the suitable container for receiving an edible fat-based material) at least one receptacle associated with loosening means such as a hopper (s) with an inflatable liner.

[0133] Optionally in this further embodiment, the apparatus of the invention additionally comprises a receptacle comprising an inlet hole and at least one tapered inner surface and an outlet hole, with loosening means deposited on or close to one or more of the inner surface tapered portion of the container to reduce or eliminate the tendency for material to adhere to at least one interior surface and to assist in transporting the material within the container from the inlet port to the outlet port.

[0134] Preferably the loosening means comprises at least one flexible, reversibly deformable surface forming at least part (optionally all) of the inner surface of the container where (i) the flexible surface comprises at least two opposing edges (preferably three edges , more preferably four edges, most preferably substantially all, e.g. the entire circumference edge) secured to the inside of the container; and (ii) a substantial part (optionally all) of the flexible surface except the pinned edges can be reversibly deformed such that at least part (optionally all) of the flexible surface except the pinned edges is free to move in an inward direction in the opposite direction to the outside of the container and/or the inside surface of the container to which it is adjacent; (iii) the flexible surface that forms at least part (optionally all) of the interior surface of the container exposed to its contents.

[0135] More preferably, the interior of the flexible surface (e.g. the surface coating) comprises material that is suitable for contacting food, and most preferably the flexible surface consists of material approved for contacting food .

[0136] During use, the flexible surface can be controlled to deform the inner surface and/or profile of the receptacle sufficiently to loosen and substantially remove any fat-based material that has adhered to it, to assist in the transport of the material inside the container from the inlet hole to the outlet hole.

[0137] In a preferred receptacle at least one of the flexible deformable surfaces comprises a diaphragm controlled by one or more actuators (optionally hydraulically operated) optionally repeatedly at a suitable frequency, to change the shape of the diaphragm to prevent and/or remove adhesion of the material thereto, and optionally such surfaces may form part of the control means, as described herein.

[0138] More preferably, at least one of the deformable flexible surfaces comprises part of a substantially fluid-tight flexible bladder, the internal pressure of which optionally can be adjusted to change the shape of the surface of the bladder forming the interior of the container to avoid and/or remove the adhesion of the pasty mass to it.

[0139] At least one of the flexible bladders can be filled or deflated with gas to reversibly deflate and/or inflate the bladder or alternatively at least one of the flexible bladders can be filled or emptied with liquid which can be operated reversibly to deform the bladder surface hydraulically (eg using a piston and reservoir chamber). The shape and/or internal profile of the surface of the bladder forming part of the interior of the container will thereby be altered and this can be used to prevent material from adhering and/or to remove material already adhered to the surface. Optionally these changes can be repeated at a suitable frequency (eg resonant frequency) that has been shown to be most effective in removing material. The control of the loosening means can also be used with suitable sensors to adapt their operation to the properties of the material being conveyed optionally in real time (for example as part of the control means of the present invention). For example, the receptacle may comprise at least one bladder, diaphragm and/or removable surface which may together form the entire tapered interior surface of the receptacle to form a flexible deformable inner liner thereon.

[0140] Optionally, in this additional embodiment, the process of the invention additionally comprises pre-steps (D) (E) and (F) performed before steps (a) and (b) of: (D) adding the edible material to the fat base to a receptacle comprising an inlet port; and outlet port and at least one tapered interior surface provided with loosening means located on or close to it, the outlet port of the receptacle being in fluid connection with the inlet conduit of the processing chamber; (E) operating the loosening means sufficiently to loosen and/or substantially remove the fat-based material adhered to the interior surface; (F) conveying the fat-based material from the receptacle to the energy application means used in step (a) through the receptacle outlet port and the processing chamber inlet conduit.

[0141] Usefully in another embodiment of the process of the invention, the fat-based material is added and/or conveyed within a receptacle, as described above.

[0142] Conveniently, the loosening step (E) comprises reversibly deforming the flexible surface to move the surface in an inward direction as opposed to the outside of the container.

[0143] Preferably, the fat-based edible material used in the present invention is a fat-based confectionery composition, more preferably a chocolate material, most preferably a chocolate material comprising solids and fat. As used herein, the terms "refining", "refining" or "refining" refer to the general process of reducing the particle size of solids in an edible fat-based material of and/or used in the present invention through any means Suitable, as the apparatus described herein, is a roller refiner, mill, mixer and/or any other similar apparatus. Optionally, during refining, the solid particles in the fat-based material are present as agglomerates, and these solid agglomerates may be reduced in size or eliminated by treatment in at least one of the refining pre-steps described here before the viscosity is determined. reduced (preferably liquefied) in steps (a) and (b).

[0144] In yet another embodiment, the apparatus and/or process of the invention may comprise and/or use (for example, as the outlet conduit in fluid connection with the processing chamber of a refiner in one or more pre-steps ) a vertical outlet tube.

[0145] In this additional embodiment of the invention, the apparatus of the invention additionally comprises a pre-refiner located before the processing chamber that has an outlet conduit in fluid connection with the inlet conduit of the processing chamber so that the refiner outlet is an intermediate that can be used directly in step (a) and (b) of the present invention.

[0146] Optionally, a receptacle provided with loosening means associated with it, as described here, can be provided before the refiner and/or between the refiner outlet and the processing chamber inlet (maintaining the fluid connection between them) to reduce or eliminate the tendency for grease to stick to the appliance. The refiner outlet port and receptacle outlet will generally be different from the outlet conduit from the processing chamber of step b) as the refiner outlet and/or outlet of at least one receptacle can be the input in steps a) and b).

[0147] In addition, a means can be provided to adjust the material pressure (increase or decrease) between exiting the refiner outlet port and before the refined material enters the processing chamber entry port. Suitably, the pressure adjusting means is a gear pump, lobe pump, piston pump, vacuum pump and/or an extruder. Most conveniently, the material pressure experienced in the pre-refining step is higher than that in the viscosity reduction step. Even more conveniently, solid ingredients can be added, mixed with fat and/or emulsified (for example using a mixer) before the material is pressurized with the pressure generating means. Alternatively, solid ingredients can be added, blended with fat and/or emulsified before the material is depressurised with a pressure reducing means.

[0148] Even more optionally, the refiner outlet can be oriented substantially vertically above the inlet conduit processing chamber, so that the material can be fed into it, in whole or in part, under gravity.

[0149] Most optionally still, the refiner can be oriented to the main axis of the material flow path through the refiner that is substantially horizontal with the refiner outlet oriented perpendicularly to the main axis and substantially vertically above the processing chamber of the inlet conduit, so that the material can be fed into it, in whole or in part, by gravity.

[0150] Advantageously, the refiner may comprise a horizontally oriented Lipp mixer. As used herein, the term "Lipp mixer" denotes horizontal axis high shear mixers commercially available from Lipp Mischtechnil of Germany that are designed for and indicated by the manufacturer as suitable for conching chocolate. A Lipp mixer is capable of substantially breaking down the agglomerates and intimate interactions of solids with fat within the fat-based material to intermediately produce a pasty or powdery mass with fat coating the solid particles therein. However, it will be recognized that any other suitable refiner known to those skilled in the art can also be used.

[0151] The refiner is preferably capable of substantially disrupting agglomerates and intimate interactions of solids with fat within an edible fat-based material before the material is used in steps (a) and (b). Then, the refined material produced by the refiner can be an intermediate mass in which the solids are substantially coated with the fat, for later use in step (a) and (b) of the present invention. This intermediate refined material may be referred to as flake (or, when the fat-based material is chocolate, chocolate flake). The advantage of a pre-refining step is to reduce the energy requirements for reducing the viscosity in steps (a) and (b) and thereby reduce the amount of total specific work that may need to be imparted according to equation (1) which may be less.

[0152] The intermediate refined material obtained and/or obtainable by a refining step (as at least one pre-step as described herein) can be used directly and/or immediately in steps (a) and (b) of the process of the invention optionally without additional pre-steps. Especially for chocolate flake it is generally preferable to use flakes immediately and directly in the next step (eg liquefaction) (ie the fresher the flake the better). However, alternatively the refined intermediate material obtained and/or obtainable by refining can be collected and stored for later use in steps (a) and (b) of the process of the invention and/or in other subsequent steps to develop the physicochemical properties , flavor and/or mechanics of the material.

[0153] It is an optional advantage of the present optional invention that, for many fat-based materials, the pre-refining step can be eliminated or have its time reduced since the process of the invention allows for an improved and efficient control of reducing the viscosity and, for example for some fat-based materials, a combined refining and liquefaction step may be possible. For highly agglomerated materials (for example having in them a significant proportion of large particles of solid agglomerates) a pre-refining step can still be useful, as equipment such as refining cylinders are ideally designed for and particularly effective in deagglomeration ( grinding of solid particles into smaller sizes) to produce flakes, although they are perhaps less suitable as the means of applying energy for reducing viscosity and/or flake liquefaction in steps (a) and (b). However, if a pre-refining step is optionally used, where it makes sense, the refiner can also be operated analogously to steps (a) and (b) using the relationship in equation (1).

[0154] In yet another embodiment, the refiner comprises a high shear mixer which produces as an intermediate a refined or pasty powdered mass (preferably powdered mass) for use in step (a) and (b) of the present invention.

[0155] Preferably, even in this additional embodiment, the process of the invention additionally comprises pre-steps (G) and (H) performed before steps (a) and (b) of: (G) refining the edible material based on of fat in a refiner with an outlet fluidly connected to the inlet conduit and processing chamber used in step (a), subjecting the material to at least 200,000 s-1 shear (high shear) long enough to form a powdered or pasty mass (preferably a powdered mass), which is used directly in steps (a) and (b), (H) conveying the high shear refined powdery or pasty mass (preferably the high shear mass powder) from step (E) through the outlet and inlet conduit to the energy application means used in step (a).

[0156] Preferably in step (G) the refiner is oriented substantially horizontally with respect to the outlet and the inlet conduit which are oriented substantially vertically so that the powdered or pasty mass (preferably the mass in powder) is transported to the energy release means, totally or partially, under the action of gravity.

[0157] In another embodiment, the refiner is a low-energy, low-shear mixer that produces as an intermediate a refined paste or powder mass (preferably a paste paste) for use in steps (a) and (b) of the present invention. In yet another embodiment, the apparatus and/or process of the invention may be used in and/or comprise an additional low shear premixing step.

[0158] A process, as defined in any of the foregoing embodiments, the process further comprising pre-steps (J) and (K) performed before steps (a) and (b) of: (J) refining the fat-based edible material having solid agglomerates therein in a refiner with an outlet fluidly connected to the inlet conduit and processing chamber used in step (a), subjecting the material to a maximum shear of 200,000 s-1 (low shear) and a total mixing energy of maximum 1000 kW (low energy) calculated at a material flow rate of 20 kg/minute; wherein low shear, low energy mixing is carried out long enough to substantially break down the agglomerates and intimate interactions of any solids with the fat to produce a pasty or powdery mass (preferably pasty mass) in which the solids contained therein are substantially coated with fat; pasty or powdery dough (preferably pasty dough) being used directly in steps (a) and (b); and (K) conveying the refined low-shear, low-energy slurry from step (J) through the outlet and inlet conduit to the energy application means used in step (a).

[0159] Step (J) can be performed using a method known as a conventional ladle.

[0160] As used herein, the term low shear (for example in some of the embodiments described herein) conveniently denotes the application of shear forces to a material such that the peak shear applied to the material is not greater than 200,000 reciprocal seconds. More conveniently, low shear denotes that the shear is less than or equal to 150,000s-1. An even more convenient degree of low shear (for example the use of a low shear pre-mixing step as described here) can be from 1000s-1 to 150,000s-1, more conveniently from 5000s-1 to 120,000s-1 , for example, from 10,000s-1 to 100,000s-1.

[0161] As used herein, the term low mixing energy (for example, in some of the embodiments described herein in a pre-step) denotes a total amount of mechanical energy imparted to a material by a low shear mixer of a maximum of 100 kJ, preferably less than or equal to 50 kJ, most preferably less than or equal to 1000 kJ, most preferably less than or equal to 100 kJ, based on a material flow through the mixer of 50 kg per minute. The flow rate of material through a low shear mixer in a pre-stage used in one embodiment of a process of the invention can be from 1.5 to 100 kg per minute and thus, for example, the amounts of total energy applied to the material can be adjusted accordingly for a given flow rate to impart low total mass energy values that fall within the values given above. It will be recognized when a material is used in a premixing step outside of step (a) and (b) of the present invention, that the amount of work imparted by such premixing may be outside the relationships described here in equation (1 ) and/or (2), although it is also possible that these relationships are satisfied.

[0162] Optionally, a low degree of work that can be achieved in a premixing step used in an embodiment of the invention, can be performed by operating the low shear mixer at a power of a maximum of 100 kW (low mechanical energy ), preferably less than 50 kW, most preferably less than 1000 kW per kilogram of mixed material (e.g. a pasty mass).

[0163] A low shear mixer may comprise a rotating drive shaft with paddles or the like deposited thereon, and to substantially prevent high shear amounts being experienced by the mixed material, it is preferred that the low shear mixer be operated at a rotational speed of less than 300 rpm, more preferably less than 200 rpm, most preferably less than 100 rpm, and most preferably less than 50 rpm. Advantageously, the impeller in such a low shear mixer is operated at a rotational speed of from 1 to 300 rpm, more preferably from 5 to 200 rpm, even more preferably from 10 to 100 rpm, and most preferably from 20 to 200 rpm. 50 rpm.

[0164] Conveniently, low shear mixing can be achieved by passing the material under reduced pressure through a twin screw filler, most conveniently by elongated flow through such a filler.

[0165] All aspects of the embodiments described herein may also be controlled by control means in addition to the control means used as described herein to control the energy application means. This presents a method for providing overall control of the entire process of the invention which can be fully or partially automated.

[0166] Yet another aspect of the invention provides an edible fat-based material obtained and/or obtainable by a process of the present invention. The products of the invention are edible food products (or components thereof as a filling), usefully the food product is a fat-based food product, more advantageously fat-based confectionery products, even more advantageously a food product comprising a composition of chocolate, and more usefully a food product comprising (e.g. consisting of) chocolate and/or compound.

[0167] A process embodiment of the invention provides a fat-based material (preferably chocolate material, for example chocolate or compound) of consistent predetermined viscosity, and a product embodiment of the invention also encompasses the fat-based material consistency (preferably chocolate material, e.g. chocolate or compound) so produced. Preferred products of the present invention have a viscosity (PV) of 2 to 6 Pa.s, more preferably 3 to 5 Pa.s.

[0168] The product obtained directly or indirectly from a process of the present invention (for example, from steps a) and/or b)) can be collected and stored for later use or used immediately in later steps.

[0169] Optionally, the product of the present invention comprises the fat-based material as a continuous phase within which the moisture content is present dispersed as droplets and/or as a coating on the surface of hydrophilic particles, such as, for example, sugar particles. Preferably, the dispersed droplets are substantially homogeneous in size (eg as defined by a DSD, as described herein). Advantageously, the dispersed droplets are dispersed substantially homogeneously within the fat-based material (i.e., so that the droplets seen in any given sample are typical and representative of the entire material) regardless of the viscosity of the material, i.e., whether the continuous phase is a low viscosity free flowing liquid or a viscous liquid or a solid. The dispersed water may be present as single-phase droplets (where the product comprises a water-in-oil (w/o) emulsion) and/or as droplets of a multiphase fluid (where the product comprises an oil-in-oil emulsion). water in oil (o/w/o)).

[0170] Preferably, the dispersed water droplets (or water-containing droplets) are small enough to be invisible to the naked eye (ie, smaller than 100 microns) to have minimal impact on the visual appearance of the final product.

[0171] As discussed above, one of the advantages of the process of the invention is that, surprisingly, liquefaction of a fat-based material can be achieved with larger amounts of water present than previously thought to be possible. Therefore, the products of the invention can be prepared with a high moisture content which has either not been achieved before in prior art fat-based compositions (especially for chocolate materials such as chocolate or compound) or has never been achieved before or with low cost on an industrial scale.

[0172] Therefore, broadly in accordance with another aspect of the invention, there is provided a fat-based edible product (usefully a chocolate material) which does not have a low moisture level (as defined herein) and preferably that has a high level of humidity (as defined here).

[0173] In yet another embodiment, a fat-based product of the present invention (especially when comprising or consisting of a chocolate material such as chocolate and/or compound) suitably has a moisture content of at least 1.3%, plus conveniently at least 1.4%, more conveniently at least 1.5%, even more conveniently at least 1.8%, and most conveniently at least 2.0%, for example, of at least 2.5% by weight of the total weight of the product. In that embodiment, such fat-based products of the invention can be prepared by any suitable process compatible with the process of the invention (and thus also include products such as chocolate and/or compound prepared by a crumbling process). These "wet" products are even wetter than those typically prepared by a crumbling process (having 1.2% moisture by weight).

[0174] In this embodiment, a fat-based product of the present invention (especially when it comprises or consists of a material chocolate material such as chocolate and/or compound) has a moisture content advantageously of 1.3% to 5%, more advantageously from 1.5% to 4.5%, even more advantageously from 1.8% to 4.0%, and most advantageously from 2.0% to 3.5%, for example 2.0% to 3.0% by weight, based on the total weight of the product, usefully on the total weight of chocolate and/or compound.

[0175] In embodiments of the products of the invention described herein that comprise a chocolate material (such as chocolate and/or compound), it is preferred that the moisture content of the product is less than or equal to 1.2% by weight the product being obtained by a process other than crumbling. Such uncrumbed products still have a higher moisture content than previously obtainable through other processes (such as conching) where low moisture content (less than 0.8%) was believed to be required.

[0176] Therefore, in yet another embodiment, a fat-based product of the present invention (especially when comprising or consisting of a chocolate material such as chocolate and/or compound prepared by processes other than crumbling) has a moisture content of at least 0.8%, profitably at least 0.9%, more profitably at least 1.0%, and most profitably at least 1.1%, e.g. at least 1.2%, by weight, based on the total weight of the product, preferably based on the total weight of the chocolate and/or compound.

[0177] In a further embodiment, a fat-based product of the present invention (especially when comprising or consisting of a chocolate material such as chocolate and/or compound, prepared by processes other than crumbling) has a moisture content advantageously of 0.8% to 5%, more advantageously from 0.9% to 5.0%, even more advantageously from 1.0% to 4.5%, and with a maximum advantage of 1.1% to 4%, for example 1.2% to 3% by weight, based on the total weight of the product, preferably on a basis of weight of the chocolate and/or compound.

[0178] A process embodiment of the invention provides a fat-based material (preferably chocolate material, for example chocolate or compound) of consistent predetermined viscosity, and a product embodiment of the invention also encompasses the consistent fat-based material (preferably chocolate material, e.g. chocolate or compound) so produced. Preferred products of the present invention have a viscosity (PV) of 1 to 12 Pa.s, preferably 1.5 to 10 Pa.s, more preferably 2 to 6 Pa.s, and most preferably 3 to 5 Pa.s.

[0179] In yet another embodiment, the product of the present invention is an edible fat-based material, which has at least one of the following parameters. I) a viscosity (PV) of 2 to 6 Pa.s, usefully 3 to 5 Pa.s; II) an elastic limit (YS) of 4 to 10 Pa, conveniently 5 to 8 Pa; and/or III) a moisture content, preferably at least 0.8% to 5%, more preferably 1.3% to 5.0%, most preferably 1.5% to 4.5% % by weight, most preferably from 1.8% to 4.0%, for example from 2.0% to 3.5% by weight, based on the total weight of the fat-based material.

[0180] A particularly preferred product of the present invention has a viscosity (PV) of 2 to 6 Pa.s and a moisture content of 1.3% to 5.0%, by weight of the product.

[0181] In another embodiment, the process and material of the invention can also be used to produce material suitable for spraying.

[0182] Fat-based edible materials with a low fat content are highly viscous and are therefore unsuitable for certain applications, for example for application by means of spraying. Therefore, additional fat (where the material is chocolate, typically cocoa butter) needs to be added in an additional minimum amount of 25% by weight, and often in amounts as high as 50% more fat by weight, to reduce the viscosity of the material sufficiently so that it can be sprayed. The exact viscosity required for spraying can vary by batch of material, spraying conditions and temperature, but can typically be from 2 to 6 Pa.s. Spraying is a useful means of depositing fat-based materials such as chocolate more precisely and cost-effectively onto a substrate (eg product), producing less waste and thinner coating weight. However, sprinkling is not widely used given the need to have a high fat content. Materials with a high fat content can be undesirable from a health point of view when the trend is to reduce the fat content, especially in confectionery products such as chocolate. Cocoa butter is also a very expensive ingredient, so high-fat chocolate will be more expensive to produce (and other fats may typically not be added instead of cocoa butter if the product meets the legal definition of chocolate).

[0183] Thus, it was believed to be impossible (or effectively impractical) to obtain a low-fat edible fat-based material (such as low-fat chocolate) that also had a sufficiently low viscosity that the material could be sprayed.

[0184] Surprisingly, it has been found that the preparation of an edible fat-based material such as chocolate according to the process of the invention allows the viscosity to be reduced to low levels even with a low fat content, and thus , the material can be sprayed without adding more fats (such as cocoa butter).

[0185] Therefore, in a further aspect of the present invention, there is provided the use in a spraying process of an edible fat-based material that has a low fat content of, for example, 50% by weight of the total weight of the material, whereby the material is prepared in the process of the invention to have a low viscosity, for example 6 Pa.s or less.

[0186] In yet another aspect of the present invention, a process is provided for sprinkling an edible fat-based material on a substrate, the material having a low fat content of, for example, 50% by weight of the total weight of the material, whereby the material is prepared in the process of the invention to have a low viscosity, for example 6 Pa.s or less.

[0187] The spraying can be carried out at a reduced temperature (cooled) lower than the ambient temperature, more preferably at a temperature of 5°C to 18°C.

[0188] The low-fat, low-viscosity material used in the spraying process can be transformed in the process of the invention by an energy application means comprising a combination of elongational/extensional shear, along with high-speed shear

[0189] The fat-based edible material may preferably comprise a fat-based confectionery composition, more preferably comprising a chocolate material, most preferably chocolate or composed of, for example, chocolate.

[0190] As used herein, low fat denotes an edible fat-based material that has a fat content of less than 50% by weight.

[0191] As used herein, high fat denotes an edible fat-based material that has a fat content of at least 50% by weight.

[0192] The process and material of the invention can be used to produce material containing highly stable seed crystals, the presence of which can usefully improve product quality. Accordingly, this aspect of the present invention features fat-based materials (the material preferably comprising a chocolate material, more preferably comprising chocolate or composite, most preferably being chocolate) that have greatly improved heat stability. since the inherent stability of fat crystals within a fat system can be maximized. In one embodiment of the invention, the process of the invention can be used to increase the proportion of stable polymorphs that are formed from symmetrical triglycerides within a fat-based material. Preferred symmetrical triglycerides may comprise cocoa butter (MC), but this is just an example. This aspect of the present invention can also be used to generate fat-based material (such as fat-based powders) that have improved stability even at a low fat content (eg low saturated fat content). Such fat-based materials have been found to readily retain their shape when processed, for example when compressed into tablets.

[0193] Beckett (4th edition) in chapter 12, section 12.2, explains that: "Polymorphism is the ability of a molecule to crystallize in a number of different crystal packing configurations. Although polymorphism is present in most fats, fats rich in symmetrical monounsaturated triglycerides such as SOS (ie, whose structures are saturated fatty acid-oleic acid-saturated fatty acid) are highly polymorphic. This high degree of polymorphism is not only found in cocoa butter, but also in fats rich in cocoa SOS used in cocoa butter equivalents"

[0194] Tempering chocolate batter can be difficult when the batter contains cocoa butter of poor quality caused by seasonal variation or indulgent recipes (ie, having a higher than typical fat content). Tempering is the process by which the proportion of crystals that have different polymorphic forms (polymorphs) is changed to improve the chocolate, for example by melting the less stable polymorphs and recrystallising the chocolate to have more of the more stable polymorphs. Tempering in this way can improve the stability of the chocolate (e.g. its ability to resist fat migration such as fat bloom) and a high proportion of stable polymorphs can also improve appearance and feel. of the chocolate (create a brighter appearance and/or a high degree of chocolate "crunchiness").

[0195] It would be desirable to improve the properties of an edible fat-based material of the invention by more easily forming a high proportion of more stable polymorphs, for example by increasing the amount of polymorphs that are generated locally and/or also by the reduction of generation of or removal of less stable polymorphs. Ideally this can then eliminate and/or reduce the need for a separate post tempering step.

[0196] In prior art processes, polymorphs that can act as stable seed crystals can be separately obtained or prepared, and then added to a fat-based material during manufacturing to promote the generation of more stable polymorphs thereof type on the material to which they are added. In this way, the (seeding) method can be used to improve the stability and other properties of a fat-based material to avoid or reduce the need for an additional tempering step. For example, form VI polymorph rich cocoa butter starters can be produced by commercially available machines such as that available from Buhler under the trade designation Seed Master. However, adding starting particle material in this way to a process creates complications, as there is then a serial increment in crystal content if the fat-based material is recycled and reintroduced to the process before the seeding step, as this is typically the case when, for example, chocolate is used to coat a product.

[0197] Regardless of the quality of the cocoa butter used or the complex mixture of fats in a given chocolate recipe, in an industrial process, the only practical method available to process chocolate is conventional tempering which is based on cooling and which tends to favor the formation of less stable polymorphs. Conventional tempering seriously compromises the quality of chocolate produced in a factory.

[0198] Surprisingly, the applicant has found that using the process of the invention to prepare an edible fat-based material promotes unusual crystallization behavior in the material. For example, the process of the invention can be used to produce chocolate comprising high proportions of more stable MC polymorphs, such as Form VI and Form V beta polymorphs, the chocolate having a high proportion of readily obtainable Form VI. The process of the invention can advantageously be further controlled using additional parameters such as pressure, chocolate temperature and cooling temperature to achieve high ratios or the desired polymorph. Additional seeding steps can be avoided, and further tempering steps can be reduced or eliminated altogether.

[0199] As used herein, the preferred polymorphs for cocoa butter obtained and/or obtainable by a process of the invention are characterized by an X-ray diffraction (XRD) with a strong line at 4.6 Â (Angstrom = 1 x 10 -10 m). These polymorphs are well known to those skilled in the art and are described, for example, in Beckett (4th edition) chapter 12 (XRD shown in Figure 12.3) as the beta (β) form, which term encompasses both the MC V polymorph (also called Form V or β2 or βv) as well as the MC VI polymorph (also called Form VI or β1 or βvi). Form VI is more stable than Form V and therefore preferred; thus, fat-based materials with a high proportion of Form VI are even more preferred.

[0200] Therefore, in another aspect of the present invention, the use of a process of the present invention is presented for the purpose of producing an edible fat-based material (the material preferably comprising a chocolate material, more preferably comprises chocolate or compound, most preferably being chocolate) such that the material comprises a high proportion (at least 50 parts by weight) of a desired polymorph based on 100 parts by weight being the total amount of material .

[0201] Advantageously, the desired polymorph(s) is/are at least one crystalline form of at least one symmetrical triglyceride, more advantageously, is the beta (β) form of cocoa butter, and with the maximum advantage, is Form VI of MC.

[0202] The high proportion of desired polymorph is present in a total amount usefully of at least 60 parts, more usefully of at least 70 parts, even more usefully of at least 80 parts, with the maximum use of at least 90 parts, being for example substantially 100 parts by weight based on 100 parts being the weight of the material. Conveniently, the above amounts of the desired polymorph can also be calculated (especially when the desired polymorph is beta MC or Form VI) with respect to 100 parts by weight being the total amount of cocoa butter present in the material, and more conveniently 100 parts by weight being the total amount of crystalline cocoa butter present in the material.

[0203] The desired polymorph (such as beta MC or Form VI) can be used as and/or to form stable seed crystals that favor the growth of the most desired polymorph, for example, in the presence of additional material that is a source of the molecule (such as MC) that forms the desired polymorph (optionally the additional material being amorphous, liquid; non-crystalline and/or a less stable polymorph than the desired polymorph). The desired polymorph can be added to the additional material or the additional material can be added to the desired polymorph such that the desired polymorph is in excess in place and better able to promote the formation of crystals that occupy the desired polymorph.

[0204] A further aspect of the present invention provides an edible fat-based material (the material preferably comprising a chocolate material, more preferably comprising chocolate or compound, most preferably being chocolate) which has a high proportion of a desired polymorph, the material being prepared by the process of the invention.

[0205] A further aspect of the present invention provides a process for an edible fat-based material (the material preferably comprising a chocolate material, more preferably comprising chocolate or composite, most preferably being chocolate) comprising a high proportion of a desired polymorph, the process comprising steps (a) and (b) of the process of the invention and optionally the process being free of steps comprising additional tempering and/or the addition of crystals- seed.

[0206] The material of the invention which has a high proportion of a desired polymorph (which can for example act as seed crystals therein) can be transformed in the process of the invention by an energy application means as described herein.

[0207] Optionally, the chocolate liquefied by the process of the invention can be further processed by spraying optionally at a reduced temperature (cooled) lower than room temperature, more preferably at a temperature of 10°C to 27°C to generate quantities augmented doses of a desired polymorph (such as beta CG, for example Form VI).

[0208] The products of the invention optionally comprise fat (heat) bloom resistant chocolate, chocolate that has a longer shelf life and/or better quality chocolate due to the greater proportion of stable polymorphs present (i.e. higher degree of tempering).

[0209] When chocolate is exposed to heat, in addition to the observation of fat blooming ("bloom"), another quality defect that will occur is the deformation of the format. Previous attempts to solve this problem have proved unsatisfactory. For example, water or glycerol can be added to chocolate to alter the sugar lattice to resist warping, but this involves a significant change in the chocolate-making process, adds complexity, and can have a negative impact on flavor or other desired properties. on the product (e.g. clean label).

[0210] Applicant has surprisingly found that chocolate prepared continuously by the viscosity reduction process of the invention is stronger than prior art chocolate of similar recipe prepared using conventional conching. Heat resistance can be shown by better shape retention and/or less oil separation after heating (typically 37°C test temperature) than prior art chocolate.

[0211] Therefore, in a further aspect of the present invention, there is provided the use of a process of the present invention for the purpose of producing an edible fat-based material (preferably a chocolate material, most preferably chocolate) which has better heat resistance (e.g. better shape retention and/or less oil separation after heating to 37°C) compared to the same fat-based material prepared in an identical manner, except that it is reduced in viscosity by a process different from that of the present invention.

[0212] A further aspect of the present invention provides an edible heat-resistant fat-based material (preferably a chocolate material, more preferably chocolate) (e.g. better shape retention and/or less oil separation after heating to 37°C), the material being prepared in the process of the invention. Examples 5 and 6 and the reference Comparative Example B and Comparative Example C, below, together with Figures 4 to 7, illustrate this aspect of the present invention.

[0213] Without being bound by any theory, the applicant believes that following the process of the invention can more effectively and efficiently reduce the average distance between the constituent particles within the fat-based material, preferably at submicron distances, and this can reduce the distance between particle surfaces sufficiently to promote greater interaction and thereby reduce the energy required for crystallization.

[0214] Additional aspects of the invention and preferred features thereof are presented in the claims of the present invention, which form an integral part of the disclosure of the present invention, regardless of whether such claims directly correspond to parts of the description of the present invention.

[0215] Certain terms used in the present invention are defined and explained below, unless from the context, their meaning clearly indicates otherwise.

[0216] In the context of the present invention, terms such as "fat-based" and/or "fat-based edible product" denote a composition, preferably a chocolate confection, which comprises a matrix of edible hydrophobic material (e.g. fat) as the continuous phase and a dispersed phase comprising solid particles dispersed in the edible hydrophobic continuous phase.

[0217] Within the context of the present invention, the term "fat" as used herein denotes hydrophobic material that is also edible. Thus, fats are edible (preferably food grade) materials which are substantially immiscible with water and which may comprise one or more solid fats, liquid oils and/or any mixtures thereof. The term "solid fat" denotes edible fats that are solid under standard conditions, and both the terms "oil" and "liquid oil" (unless the context otherwise indicates) denote edible oils that are liquid under standard conditions.

[0218] The preferred fats are selected from one or more of the following: coconut oil, palm kernel oil, palm oil, cocoa butter (MC), cocoa butter equivalents (CME), cocoa butter substitutes (CBS), cocoa butter replenishers (CBR), butter oil, lard, tallow, oil/fat fractions such as lauric acid or stearic acid fractions, hydrogenated oils and mixtures thereof, as well as fats which are typically liquid at room temperature like any vegetable or animal oil. However, fats that are most preferred for use in the present invention in preparing the microaerated chocolate materials of the present invention are MC, EMC, CBS, CBR and/or any mixtures and/or combinations thereof.

[0219] The liquid oil may comprise mineral oils and/or organic oils (oils produced by plants or animals), particularly food grade oils. Examples of oils include: sunflower oil, rapeseed oil, olive oil, soybean oil, fish oil, linseed oil, safflower oil, corn oil, kelp oil, cottonseed oil, seed oil oilseeds, oilseed fruit oils such as peanut oil, palm oil, palm kernel oil, coconut oil, and emerging seed oil crops such as high oleic sunflower oil, high oleic rapeseed oil oleic oil, high oleic palm oil, high oleic soybean oil, and high oleic sunflower oil or combinations thereof.

[0220] The fat content in the product of the present invention can be provided by fats of any origin. The fat content is intended to indicate the total fat content in the composition, which comprises the content from solid fats and/or the liquid oil content, and therefore the oil content will also contribute to the total amount of fat content. , as described in the present invention for the fat-based confectionery compositions of the invention.

[0221] The term "fat-based composition and/or dough" identifies, respectively, a fat-based composition and/or dough (including its recipes and ingredients) that is used for the preparation of the products of and/or used in the invention.

[0222] The term "fat-based confectionery composition and/or mass" identifies a confectionery composition and/or mass (including its recipes and ingredients) that is used for the preparation of fat-based confectionery products , like the chocolate material of and/or used in the invention.

[0223] The present invention specifically relates to a confectionery product, composition and/or mass comprising chocolate material (preferably chocolate and/or composite, more preferably chocolate), as defined herein, as well as optionally other confectionery products and/or components thereof.

[0224] The term "chocolate", as used herein, denotes any product (and/or component thereof if it were a product) that meets a legal definition of chocolate in any jurisdiction and also includes a product (and/or a component thereof) in which all or part of the cocoa butter (MC) is replaced by cocoa butter equivalents (CME) and/or cocoa butter substitutes (CBR).

[0225] The terms "chocolate compound" or "compound", as used herein (unless the context clearly indicates otherwise), denote chocolate-like analogues characterized by the presence of cocoa solids (which include cocoa liquor/mass , cocoa butter and cocoa powder) in any quantity; however, in some jurisdictions, the compound may be legally defined by the presence of a minimum amount of cocoa solids.

[0226] The term "chocolate material", as used in the present invention, denotes chocolate, compound and other related materials comprising cocoa butter (MC), cocoa butter equivalents (CME), cocoa butter replenishers (CBR , for "cocoa butter replacers") and/or cocoa butter substitutes (CBS, for "cocoa butter substitutes"). Thus, chocolate material includes products which are based on chocolate and/or based on chocolate analogues, and thus, for example, can be based on dark, milk or white chocolate and/or compound.

[0227] Unless the context clearly indicates otherwise, it will also be understood that, in the present invention, any chocolate material may be used to replace any other chocolate material, and neither the term "chocolate" nor "composite" shall be used considered as limiting the scope of the invention to a specific type of chocolate material. A preferred chocolate material comprises chocolate and/or compound, more preferably, the chocolate material comprises chocolate as legally defined in a major jurisdiction (such as Brazil, USA and/or European Union).

[0228] The term "chocolate coating", as used herein, (also referring to a "chocolate wrapper") denotes coatings produced from any chocolate material. The terms "chocolate coating" and "compound coating" can be similarly defined by analogy. Similarly, the terms "composition (or mass) of chocolate materials", "composition (or mass) of chocolate" and "composition (or mass) of compound" denote compositions (or masses) comprising, respectively, chocolate material chocolate, chocolate and compound as component(s) thereof in whole or in part. Depending on their component parts, the definitions of such compositions and/or masses can certainly overlap.

[0229] The term "chocolate material confectionery" as used herein denotes any food product comprising chocolate material and optionally other ingredients as well, and as such may refer to food products such as confectionery and wafer cookies , irrespective of whether the chocolate material comprises a chocolate coating and/or the product mass. The confectionery product of chocolate material may comprise chocolate material in any suitable form, for example as inclusions, layers, candies, pieces and/or drops. The confectionery product may further contain any other suitable inclusions, such as crunchy inclusions, for example cereals (for example puffed and/or toasted rice) and/or pieces of dried fruit.

[0230] The chocolate material of the invention can be used to mold a tablet and/or a bar, cover confectionery items and/or prepare more complex confectionery products. Optionally, prior to its use in preparing a chocolate confectionery, inclusions, as per the desired recipe, may be added to the chocolate material. As will be evident to a person skilled in the art, in some cases the product of the invention will have the same recipe and ingredients as the corresponding composition and/or dough, while in other cases, particularly when inclusions are added or for more complex products, the final product recipe may differ from that of the composition and/or mass used to prepare the same.

[0231] In a preferred embodiment of the invention, the confection of chocolate material comprises a substantially solidly molded tablet of chocolate material, bar of chocolate material and/or baked product surrounded by substantial amounts of chocolate material. Such products are prepared, for example, by substantially filling a mold with chocolate material and optionally adding inclusions and/or baked goods therein to displace the chocolate material from the mold (so-called die molding processes). wet shell), if necessary, still complete the mold with the chocolate material. For such preferred products of the invention, the chocolate material forms a substantial or total part of the product and/or a thick outer layer surrounding the inner baked product (such as a wafer and/or cookie laminate). Such solid products in which a mold is substantially filled with chocolate must be contrasted with products comprising thin molded chocolate shells which present different challenges. To prepare a thinly coated chocolate wrapper, a mold is coated with a thin layer of chocolate, the mold inverted to remove excess chocolate and/or stamped with a cold plunger to set the shape of the wrapper, and then large part, empty the mold. The mold is thus coated with a thin layer of chocolate to which additional ingredients and fillings can be added to form the inner body of the product.

[0232] Unless the context clearly indicates otherwise, it will also be well understood by one skilled in the art that the term "confectionery of chocolate material", as used in the present invention, can be readily replaced and is equivalent to the term "chocolate confectionery" as used throughout this application, and in practice these two terms, when used in the present invention, are informally interchangeable. However, when there is a difference in the meaning of these terms within the context presented herein, then chocolate confection and/or composite confection are preferred embodiments of the chocolate material confection of the present invention, a preferred embodiment being the chocolate confectionery product.

[0233] The chocolate material confectionery product may comprise one or more chocolate material products and/or chocolate material ingredients therefor, for example selected from the group consisting of: chocolate product (or products) , composite product (or products), chocolate coating (or coatings) and/or composite coating (or coatings). The products may comprise uncoated products such as bar (or bars) of chocolate material and/or tablet (or tablets) of chocolate material with or without inclusions and/or products coated with chocolate material such as biscuits, cakes, wafers and/or or other coated confectionery products. More preferably and/or alternatively, any of the foregoing may comprise one or more of cocoa butter replenisher (or replenishers) (CBR), cocoa butter equivalent (or equivalents) (CME), cocoa butter substitutes ( CBS) and/or any suitable mixture (or mixtures) thereof.

[0234] In the confectionery product of chocolate material, cocoa butter (MC) can be replaced by fats from other sources. Such products may generally comprise one or more fats selected from the group consisting of: lauric fat (for example cocoa butter substitutes (CBS) obtained from the kernel of palm fruit); non-lauric vegetable fat (for example, those based on palm oil or other special fats); cocoa butter replenishers (CBR); cocoa butter equivalent(s) (CME) and/or any suitable mixture thereof. Some EMC, CBR, and especially CBS may contain mostly saturated fat and very low levels of omega-3 and omega-6 unsaturated fatty acids (with health benefits). Thus, in one embodiment in the chocolate material confectionery of the invention, these types of fat are less preferred than MC.

[0235] An embodiment of the invention provides a multilayer product optionally comprising a plurality of layers of baked foodstuff (preferably selected from one or more layers of wafer and/or biscuit therebetween, with at least one layer of coating situated around these layers of foodstuff, the coating comprising a chocolate material of or prepared according to the invention.

[0236] A further embodiment of the invention provides a confectionery product of chocolate material, further coated with chocolate (or equivalents thereof, as a compound), for example a praline, a chocolate and/or wafer wrap product or chocolate-coated biscuit, any of which may or may not be layered. The chocolate coating can be applied or created by any suitable means, such as by coating or shaping. The coating may comprise a chocolate material or be prepared in accordance with the invention.

[0237] Another embodiment of the invention provides a confectionery product of chocolate material and/or used in the present invention comprising a filling surrounded by an outer layer, for example a praline or chocolate wrapper product.

[0238] In another preferred embodiment of the invention, the foodstuff comprises a multi-layer coated chocolate material product comprising a plurality of layers of wafer, chocolate material, biscuit and/or baked foodstuff, with a filling interspersed between the same, with at least one layer or coating being a chocolate (e.g., chocolate) material of the invention. Most preferably, the multi-layered product comprises a confection of chocolate material (e.g., as described herein) selected from sandwich biscuit(s), cookie(s), wafer biscuit(s) , muffin(s) (sweet and round cakes), extruded snacks and/or praline(s). An example of this type of product is a laminate of multiple layers of baked wafer and/or biscuit layers interspersed with filling(s) and coated with chocolate.

[0239] The baked foodstuff used in the invention can be sweet or savory. Preferred baked food products may comprise baked grain food products, which term includes food products comprising cereals and/or legumes. Most preferred are baked food products, most preferably baked wheat food products such as wafer(s) and/or biscuit(s). Wafers can be flat or shaped (e.g. in an ice cream cone or cup) and biscuits can be in many different shapes, although preferred wafers and/or biscuits are flat so they can usefully be laminated. together with a confectionery filling of the invention (and, optionally, a fruit-based filling). The most preferred wafer biscuits are unsalted wafer biscuits, for example those that have a sweet or neutral taste.

[0240] A non-limiting list of these possible baked food products that may comprise chocolate material compositions comprising chocolate material of and/or used in the present invention is selected from: high-fat cookies, cakes, breads, pasta for pie and/or fruit pies; as from the group consisting of: ANZAC biscuit, biscotti, oatmeal biscuit (flapjack), Turkish biscuit (kurabiye), gingerbread (lebkuchen), honey biscuits (leckerli), almond biscuit (macaroon), bourbon biscuit, shortbread, digestive biscuits, vanilla-filled biscuits (custard cream), florentina, garibaldi gingerbread, shortbread Greek biscuits (koulourakia), Greek biscuits (kourabiedes), Linzer pie, oreo biscuits, Nice biscuits, peanut butter biscuits, polvorón shortbread, pizzelle biscuit, pretzel, croissant, shortbread, biscuit (cookie), fruit pie (e.g. apple pie, cherry pie), lemon cake with lemon sauce, banana bread, carrot ball , pecan pie, apple strudel, baklava, Berlin dream, bichon au citron baked pastry and/or similar recipes.

[0241] Preferably, the chocolate material of or prepared according to the invention may be suitable for use as (in whole or in part as a component) of one or more coatings and/or fillings.

[0242] The coating and/or filling may comprise a plurality of phases, for example one or more fluid and/or solid phases, such as liquid water and/or fat phases, and/or gaseous phases such as emulsions, dispersions, creams and/or foams.

[0243] Therefore, broadly, a further aspect of the invention comprises a food product comprising chocolate material and/or chocolate material composition as described in the present invention.

[0244] Yet a further aspect of the invention broadly comprises the use of a chocolate material of or prepared according to the invention in the form of a confectionery product of chocolate material and/or in the form of a filling and/or coating for a foodstuff of the invention, as described in the present invention.

[0245] Unless otherwise defined, all technical and scientific terms used herein have the same meaning by which they are commonly understood by those skilled in the art to which the invention belongs.

[0246] Unless the context clearly indicates otherwise, as used herein, the plural forms of terms shall be deemed to include the singular form, and vice versa.

[0247] The terms "effective", "acceptable", "active" and/or "suitable" (for example, with reference to any process, use, method, application, preparation, product, material, formulation, composition, recipe, component, ingredient, compound, monomer, oligomer, polymer precursor and/or polymer described herein and/or used in the present invention as appropriate) shall be understood to refer to those features of the invention which, if used correctly, provide the properties required for that to which they are added and/or incorporated, to be of use as described herein. Such utility may be direct, for example, when a portion has the required properties for the aforementioned uses, and/or indirect, for example, when a portion has use as a synthetic intermediate and/or diagnostic tool and/or other tool in the preparation of another portion of direct utility. For use in the present invention, these terms also indicate that a sub-entity of the whole (such as a component and/or ingredient) is compatible with the production of effective, acceptable, active and/or suitable final products and/or compositions.

[0248] The preferred utility of the present invention comprises the use as a foodstuff, preferably as a confectionery product and/or intermediate in the manufacture thereof.

[0249] Unless the context clearly indicates otherwise, as used herein, the plural forms of terms shall be deemed to include the singular form, and vice versa.

[0250] The term "comprising" as used herein shall be understood to mean that the following list is non-exhaustive and may or may not include any other suitable additional item, for example, one or more features, components, ingredients and/or additional substitutes, as appropriate.

[0251] In the discussion of the invention, unless otherwise stated, the disclosure of alternative values for the upper and lower limit of the allowed range of a parameter coupled with an indication that one of said values is more preferable than the other must be taken as an implicit statement that each intermediate value of said parameter, which is between the most preferred and the least preferred of said alternatives, is itself preferred to said least preferred value and also to each least preferred value and to the said intermediate value.

[0252] For all upper and/or lower limits of any parameters given in the present invention, the limit value is included in the value for each parameter. It will also be understood that all combinations of preferred and/or intermediate minimum and maximum threshold values of the parameters described herein in various embodiments of the invention may also be used to define alternative ranges of each parameter for various other embodiments and/or preferences of the invention, the combination of such values whether or not specifically disclosed herein.

[0253] Unless otherwise specified, all percentages in the present invention refer to percentages by weight, where applicable.

[0254] It will be understood that the sum total of any quantities expressed herein as percentages may not (allowing for rounding errors) exceed 100%. For example, the sum of all components comprising the composition of the invention (or part (or parts) thereof) may, when expressed as a percentage by weight (or other percentage) of the composition (or the same parts thereof), total 100%, allowing for rounding errors. However, where the list of components is not exhaustive, the percentage sum for each such component may be less than 100% to allow for a certain percentage for an additional quantity (or additional quantities) that may not be explicitly described here.

[0255] The term "substantially", as used herein, may refer to an amount or entity implying a large amount or proportion thereof. Where relevant in the context in which the term "substantially" is used, it may be understood to mean quantitatively (in relation to any quantity or entity to which it refers in the context of the description) as comprising a proportion of at least 80%, preferably at least 85%, more preferably at least 90%, most preferably at least 95%, especially at least 98%, for example about 100% of the relevant total. By analogy, the term "substantially exempt" may similarly denote that the amount or entity to which it refers comprises not more than 20%, preferably not more than 15%, most preferably not more than 10% , most preferably not more than 5%, especially not more than 2%, for example about 0% of the relevant total. Preferably, where appropriate (e.g. in ingredient amounts) such percentages are by weight.

[0256] Any percentages by weight in the above parameters are calculated in relation to the initial weight of the component.

[0257] The improved properties as used herein mean that the value of the component and/or composition of and/or used in the present invention are > + 8% of the value of the known reference component and/or composition described herein, with more preference, > + 10%, even more preference, > + 12%, with maximum preference, > + 15%.

[0258] Comparable properties, as used herein, mean that the value of the component and/or composition of the present invention and/or used therein is within +/- 6% of the value of the known reference component and/or the composition described herein, more preferably +/- 5%, most preferably +/- 4%.

[0259] The percentage differences for the improved and comparable properties of the present invention refer to the fractional differences between the component and/or the composition of the invention and/or used therein and the known reference component and/or the composition described herein, where the property is measured in the same units in equal ways (that is, if the value being compared is also measured as a percentage, it does not denote an absolute difference).

[0260] Unless otherwise indicated or the context clearly indicates otherwise, all tests in this document are performed under standard conditions as also defined in this document.

[0261] As used herein, unless the context indicates otherwise, standard conditions (eg for the definition of a solid fat or liquid oil) mean atmospheric pressure, a relative humidity of 50% ± 5%, ambient temperature ( 22°C ± 2°) and an air flow less than or equal to 0.1 m/s. Unless otherwise noted, all tests in this document are performed under standard conditions as defined herein.

[0262] The texture of food products is perceived as a composite of many different characteristics that comprise various combinations of physical properties (for example, mechanical and/or geometric properties) and/or chemical properties (such as fat and/or moisture content ). As used herein in relation to the compositions of the invention, for a given fat and moisture content, the texture of the composition can be related to the viscosity of the composition as a fluid when subjected to shear stress. Provided the measurement technique is carefully controlled and the same shear rates are used, apparent viscosity can be used in the present invention as a guide to indicate texture. The term "viscosity" (as used herein, refers to the apparent viscosity of a fluid as measured by conventional methods known to those skilled in the art, but in particular the method described below is preferred. Some fluids exhibit non-Newtonian rheology and may cannot be fully characterized by a single point of rheological measurement Apparent viscosity, however, is a simple measure of viscosity useful for evaluating such fluids.

[0263] The viscosity of the compositions according to the invention and/or prepared by a method of the invention, as well as the comparative examples, (for example, chocolate materials such as chocolate) can be characterized by the plastic viscosity according to the method ICA 46 (2000).

[0264] The invention is illustrated by non-limiting Figures 1 to 6 below, in which:

[0265] Figure 1 is a graph showing the linear relationship of equation (1) for chocolate liquefaction under continuous shear mixing.

[0266] Figure 2 is a graph of viscosity versus volume fraction for various milk chocolates of different fat content.

[0267] Figure 3 shows a chocolate of the invention (Example 5) kept at 60°C for more than a week and which does not show any sedimentation.

[0268] Figure 4 shows a reference prior art chocolate (Comparative B) held at 60°C for over a week showing severe oil separation.

[0269] Figure 5 shows a chocolate tablet of the invention (Example 6) heated to 40°C and subjected to a three-time tapping test and which shows good shape retention even after heating.

[0270] Figure 6 shows a chocolate tablet of the prior art as a reference (Comparative C) heated to 40°C and subjected to a three-tap test and which shows unsatisfactory shape retention even after heating.

[0271] It should be noted that the embodiments and features in the context of one of the aspects of the present invention also apply to other aspects of the invention. While embodiments have been disclosed in the description with reference to specific examples, it will be recognized that the invention is not limited to those embodiments. Various modifications may become apparent to those skilled in the art and may be acquired from practice of the invention, and such variations are considered to be within the broad scope of the present invention. It should be understood that the materials used and the chemical details may be slightly different or modified from the descriptions without departing from the methods and compositions disclosed and taught by the present invention.

[0272] Additional aspects of the invention and preferred features thereof are provided in the claims of the present invention.

[0273] The present invention will now be described in detail with reference to the following non-limiting examples, which are to be considered for purposes of illustration only.

Examples 1 to 4 (processing dough A)

[0274] Examples 1 to 4 shown in Table 1 below are different tests of a chocolate liquefaction process, each being operated in accordance with the invention to produce the respective masses of liquid chocolate (Masses A1 to A4). In each of these examples (Examples 1 through 4) identically produced refiner flakes were pumped through a 5 inch diameter twin screw conveyor mixer (mixer commercially available from Readco) to obtain, using the settings shown in Table 1-, a respective liquid chocolate mass comprising 28.5% cocoa butter. Any of Batches A1 to A4 were suitable for use in later process steps to prepare the chocolate component of a product sold by Nestlé under the Semi Sweet Morsel® trademark. The Readco mixer was operated at different speeds and flow rates for each of Examples 1 to 4 to obtain different levels of specific work, as shown in Table 1. Table 1

[0275] It can be noted that the most preferred model used in the invention (as described in equation (1A) Iny = 0.5919 - 0.4268 ln M ) predicts the viscosity of masses A1 to A4 in a first approximation for each one of the respective Examples 1 to 4 The tests illustrated in Table 1 confirm that, following the process of the present invention, the Readco mixer can be controlled to obtain a desired target viscosity using a minimum amount of labor.

[0276] Thus, the data and examples described here show that the relationship described here in equation (1) is valid when the liquefaction is performed using a wide range of different amounts of work conferred to obtain a range of different viscosities . It is surprising that this deceptively simple relationship can be used to predict, and therefore control, a viscosity reduction process over a wide range of energy inputs.

Examples 5, 6 and comparative reference examples B and Comparative C

[0277] Examples 5 and 6 and reference examples Comparative B and Comparative C below, together with Figures 3 to 6, illustrate the aspect of the present invention that refers to the heat resistance of chocolate and whose viscosity is reduced (shelled ) according to a process of the invention.

Example 5 (Figure 3) and comparative B (Figure 4)

[0278] Applicant has surprisingly found that chocolate prepared continuously by the viscosity reduction process of the invention does not show severe oil separation after being held at 60°C for more than one week, as shown in the Figures of the present invention for Example 5 and Comparative B. As shown in Figure 4, a significant layer of fat was separated in the prior art comparative sample (Comparative B) while Figure 3 shows that no sedimentation was observed in the example of the invention (Example 5).

[0279] Without being bound by theory, this suggests that the mobility of melted fat may be highly restricted in chocolate prepared by the process described herein.

Example 6 (Figure 5) and comparative C (Figure 6)

[0280] The tablets were prepared by adding chocolate in a conventional mold. The solid tablets were then incubated at a temperature of 40°C and subjected to three "knocking" tests to assess the degree of resistance to deformation (ie the ability of the chocolate to retain its shape) after heating.

[0281] Figure 5 shows that a chocolate tablet of the invention (Example 6), prepared according to the process of the invention, undergoes minimal deformation after the "beat" tests, that is, the chocolate has good shape retention after heating.

[0282] Figure 6 shows that a Comparative C tablet of the prior art prepared by conventional conching shows very severe deformation after the "knocking" tests, that is, poor shape retention after heating. Embodiments of the present invention are defined in the following numbered clauses: 1. Process for imparting a specific work to an edible fat-based material to reduce the viscosity of the material until it reaches a predetermined target viscosity (native), where the The process comprises the steps of: (a) imparting a total amount of specific work ra to the fat-based edible material using an energy delivery means operated by one or more control parameters, both the rate and the total amount of specific work imparted to the material is determined by one or more of the control parameters; and wherein the fat-based material flows through the energy application means at an instantaneous rate at a given moment in time "t" after the start of step (a) whose flow is denoted by Qt (b) controlling the means of energy application means reaching a predetermined target viscosity (yaivo); wherein the rate of specific work done to the fat-based material is determined by controlling one or more of the control parameter(s) such that the specific work done by the means of energy application at a time t after the beginning of step (a) satisfy the relationship determined in equation 1: where: (i) eta (nt) denotes the viscosity at time t' after the start of step (a) of the fat-based material measured as plastic viscosity according to the ICA 46 method (2000); (ii) omega (ra t) denotes the total amount of specific work imparted to the fat-based material after time t' from the start of step (a) calculated from the power and flow rate as determined by equation (2) : , where: Pt denotes the power (measured in kilowatts (kW)) imparted to the fat-based material by the energy application means at time t' after the start of step (a) Qt denotes the instantaneous flow rate (measured in kg per hour (kg/h)) of the fat-based material through the energy application means at time t' after the start of step (a); and (iii) A is from 0.5 to 0.7; and (iv) B is from 0.3 to 0.6. (c) preventing the energy application means after t = T from imparting specific work to the fat-based material, the time T being determined from equations (1) and (2) and the predetermined target viscosity (target) . 2. Process as defined in clause 1 where the fat-based material is a chocolate material (preferably chocolate or compound) and the process is used to liquefy the chocolate material (i.e. predetermined target viscosity (paivo) is liquid). 3. Process, as defined above, using an apparatus having at least one sensor means associated therewith, and wherein in step (a) the sensor means measures at least one attribute of the fat-based material to generate at least one input parameter used directly or indirectly to calculate the at least one control parameter using equation (1) and optionally also equation (2). 4. Process, as defined in any of the previous clauses, whereby the average (average) power released during the duration of steps (a) and (b) is denoted as Pm which is calculated from the measurement of the instantaneous power Pt used at several different times 't' and/or calculating the average of the total power applied ra over the total duration time 'T' of step (a); and the mean (average) flow rate (measured in kg per hour (kg/h)) of the fat-based material through the energy application means released during the duration of steps (a) and (b) is denoted as Qm which is calculated from measuring the instantaneous power Qt used at several different times 't' and where the total amount of specific work that needs to be imparted to the fat-based material during steps (a) and (b) to obtain the viscosity -predetermined target (paivo) is denoted by w calculated from equation (1A): and where the total specific work is imparted to the fat-based material during steps (a) and (b) can also be determined by equation (2A): and where the time T (which is the duration over which the energy input means impart specific work ra to the fat-based edible material in step (a)) can be determined from the Pm and/or Qm s values. 5. Process as defined in any of the preceding clauses, where A is from 0.5 to 0.7. 6. Process as defined in clause 5, where A is from 0.55 to 0.65. 7. Process, as defined in clause 6, where A is from 0.57 to 0.61. 8. Process, as defined in clause 7, where A is from 0.580 to 0.605. 9. Process as defined in clause 8, where A is from 0.5900 to 0.6000. 10. Process as defined in clause 9, where A is 0.592 to 3 significant figures. 11. Process as defined in clause 9, where A is 0.5919 to 4 significant figures. 12. Process as defined in any of the preceding clauses, where B is from 0.3 to 0.6. 13. Process as defined in clause 12, where B is from 0.35 to 0.55. 14. Process as defined in clause 13, where B is from 0.37 to 0.50. 15. Process, as defined in clause 14, where B is from 0.410 to 0.440. 16. Process as defined in clause 15, where B is from 0.4200 to 0.4300. 17. Process as defined in clause 16, where B is 0.427 to 3 significant figures. 18. Process as defined in clause 17, where B is 0.4268 to 4 significant figures. 19. Process, as defined in any of the preceding clauses, for reducing the viscosity of an edible fat-based material where in step (a) the work application means comprises a mixing step using a mixing means, wherein the mixing rate is controlled by one or more of the control parameters. 20. Process, as defined in any of the preceding clauses, for reducing the viscosity of an edible fat-based material until it reaches a target viscosity of 2 to 6 Pa.s. 21. Process as defined in any of the preceding clauses, whereby the viscosity of the fat-based edible material is reduced without the need for a moisture reduction step before or during step (a). 22. Process as defined in any of the preceding clauses, where the target viscosity is 2 to 6 Pa.s and is obtained with an edible fat-based material comprising from 0.8% to 1.5%, in weight, moisture. 23. Process, as defined in any of the previous clauses, in which the means of energy application are controlled by defining and/or adjusting one or more control parameters to ensure that the specific work rate given to the material based on fat satisfies equation (1) during step (a). 24. Process, as defined in any of the previous clauses, in which the means of energy application are controlled by initially calculating the specific work rate using equation (1) and defining one or more control parameters , such that the initial rate of the energy application means remains substantially constant throughout step (a). 25. Process, as defined in any of the previous clauses, in which the specific work rate given to the fat-based material and/or the viscosity of the fat-based material are monitored during step (a) and these values are fed to an automatic control means such that one or more of the control parameters are adjusted to operate the energy application means to ensure that the specific work rate imparted to the fat-based material satisfies equation (1) throughout step (a). 26. Process, as defined in any of the previous clauses, where the control means comprises one or more sensors and/or control units operated by a computer. 27. Process, as defined in any of the preceding clauses, in which the means of energy application are controlled by one or more control parameters generated by one or more models that use equation (1) to calculate the control parameters. 28. Process as defined in any of the preceding clauses, the fat-based edible material being a fat-based confectionery material. 29. Process as defined in any of the preceding clauses, the fat-based edible material being a chocolate material. 30. Process as defined in any of the preceding clauses, the fat-based edible material being a chocolate mass or compound mass. 31. Process, as defined in any of the previous clauses, and the work rate is determined by equation (1A): 32. Process, as defined in any of the previous clauses, in which the control parameters are defined and/or adjusted using equation (1) to optimize a selected property among: the energy efficiency of the process and/or yield of the fat-based material throughout the process. 33. Process, as defined in any of the previous clauses, the process additionally comprising pre-steps (D) (E) and (F) performed before steps (a) and (b) of; (D) adding the fat-based edible material to a receptacle comprising an inlet; and outlet port and at least one tapered interior surface provided with loosening means located on or close to it, the outlet port of the receptacle being in fluid connection with the inlet conduit of the processing chamber; (E) operating the loosening means sufficiently to loosen and/or substantially remove the fat-based material adhered to the interior surface; (F) conveying the fat-based material from the receptacle to the energy application means used in step (a) through the receptacle outlet port and the processing chamber inlet conduit. 34. Process, as defined in any of the previous clauses, the process additionally comprising pre-steps (G) and (H) performed before steps (a) and (b) of: (G) refining the edible material fat in a refiner with an outlet fluidly connected to the inlet conduit and processing chamber used in step (a), subjecting the material to at least 200,000 s-1 shear (high shear) for sufficient time to form a powdered mass, which is used directly in steps (a) and (b), (H) transporting the high shear refined powder mass from step (E) through the outlet and inlet conduit to the means of energy application used in step (a). 35. Process, as defined in any of the previous clauses, the process additionally comprising pre-steps (J) and (K) performed before steps (a) and (b) of: (J) refining the edible material fat-based oil having solid agglomerates therein in a refiner with an outlet fluidly connected to the inlet conduit and processing chamber used in step (a), subjecting the material to a maximum shear of 200,000 s-1 (low shear) and a total mixing energy of a maximum of 1000 kW (low energy) calculated at a material flow rate of 20 kg/minute; wherein the low shear, low energy mixing is carried out long enough to substantially break down the agglomerates and intimate interactions of any solids with the fat to produce a pasty mass in which the solids contained therein are substantially coated with fat; the pasty mass being used directly in steps (a) and (b); and (K) conveying the refined low-shear, low-energy slurry from step (J) through the outlet and inlet conduit to the energy application means used in step (a). 36. Apparatus suitable for use in a process as defined in any one of clauses 1 to 35, the apparatus comprising: i) optionally a container suitable for receiving an edible fat-based material; ii) an inlet conduit optionally in fluid connection with the receptacle, where present, the conduit being suitable for conveying the fat-based material to a processing chamber; iii) a processing chamber comprising an energy application means, the energy application means capable of imparting specific work to the fat-based edible material within the chamber to reduce the viscosity of the material; iv) optionally an outlet conduit in fluid connection with the processing chamber, so that material of reduced viscosity can be conveyed through the outlet conduit to be collected for subsequent use and/or to another apparatus for further processing; characterized by the fact that: A) the input conduit and/or the processing chamber (and, optionally, the receptacle, when present) comprises one or more sensors that measure input parameters, the input parameters being capable of determine directly and/or indirectly: the viscosity of the fat-based edible material; and/or the specific and/or theoretical work released by means of applying energy to the fat-based material; and B) the energy application means is controllable by the control means operated by control parameters in a feedback loop to control the instantaneous amount of work delivered to the fat-based material, the control means and the means sensing devices are in direct or indirect connection, so that control parameters can be generated directly and/or indirectly in response to changes in input parameters to satisfy equation (1). 37. Apparatus as defined in clause 36 for reducing the viscosity of a fat-based mixture in a process as defined in any one of clauses 1 to 35, the device comprising an energy application means controlled by one or more more control parameters determined by equation (1). 38. Apparatus as defined in clause 36 or 37, the means of applying energy being selected from a high shear mixer, a twin screw mixer and/or an extruder. 39. Apparatus as defined in any one of clauses 36 to 38, comprising a receptacle comprising an inlet port and tapered interior surfaces and an exit port, with loosening means deposited on or near one or more of the tapered interior surface of the container to reduce or eliminate the tendency for material to adhere to said interior surfaces, the loosening means comprising at least one flexible deformable surface which is movable in an inward direction away from the exterior of the container, wherein at least two opposing edges (preferably three edges, more preferably four edges, most preferably substantially all edges of the circumference) of the deformable surface are secured to the interior of the container and a substantial portion of the deformable surface is free to move in one direction in the opposite direction to the surface of the container to which it is adjacent; wherein the movable surface forms at least a portion of the interior surface of the container exposed to its contents and consisting of material which is suitable for coming into contact with food, the flexible surface being adjustable to deform the interior surface of the container sufficiently to loosen and substantially removing any fat-based mixture that has adhered thereto, to assist in transporting the material within the container from the inlet port to the outlet port. 40. Apparatus as defined in clauses 36 to 39, the apparatus comprising a pre-refiner situated before the processing chamber having an outlet conduit in fluid connection with the inlet conduit of the processing chamber so that the outlet of the refiner is an intermediate that can be used directly in step (a) and (b) of the present invention. 41. Apparatus, as defined in clause 40, the receptacle having associated loosening means provided between the refiner outlet and the processing chamber inlet (maintaining the fluid connection therebetween) to reduce or eliminate the tendency for the dough to adhere to the appliance. 42. Apparatus as defined in clause 41, whereby a means is provided for reducing the pressure of material exiting the refiner outlet port before the refined material enters the processing chamber inlet port. 43. Apparatus, as defined in clause 42, wherein the outlet of the high shear refiner is oriented substantially vertically above the inlet conduit processing chamber, so that material may be fed into it, in whole or in part partly due to the action of gravity. 44. Control device suitable for use in conjunction with at least one of: a process of the present invention, as defined in any one of clauses 1 to 35; an apparatus as defined in any one of clauses 36 to 43; and/or an apparatus capable of being used in at least one step of a process as defined in any one of clauses 1 to 35; wherein the control device comprises at least one unit separate and/or separable from the apparatus of and/or used with the process of the invention; the apparatus comprising: at least one means for applying energy to impart a specific amount of work to an edible fat-based material to reduce the viscosity of the edible fat-based material; and at least one sensor means associated with the apparatus for generating at least one input parameter therefrom; wherein the control means comprises: at least one input interface capable of being connected with the at least one sensor means to receive at least one input parameter therefrom; and at least one output interface capable of being connected with the at least one power application means for sending at least one control parameter thereto; wherein during operation of the process of the invention; and/or apparatus of and/or used in the invention, wherein the control means is capable of: receiving via the at least one input interface the at least one input parameter of the at least one sensor means; with the use of at least one input parameter and equation (1) to calculate the at least one control parameter; and transmitting the at least one control parameter through the at least one output interface to the at least one power application means for controlling the at least one power application means to satisfy equation (1). 45. Use of a control device, as defined in clause 44, for the purpose of controlling viscosity in a process, as defined in any one of clauses 1 to 35. 46. Use, as defined in clause 45, to control a apparatus, as defined in any one of clauses 36 to 43. 47. Use, as defined in clause 46, to control an apparatus for reducing the viscosity of a fat-based material. 48. Use as defined in clause 47, the apparatus being a conventional shell. 49. Method for modifying an apparatus so that it can be used in a process, as defined in any one of clauses 1 to 35, the apparatus comprising a means of applying energy capable of reducing the viscosity of an edible material based on of fat, the method comprising the steps of: a) providing a control device of the invention; b) optionally adding sensor means to the apparatus; c) associating the control device to operate the energy application means according to equation (1) during a process for reducing the viscosity of an edible fat-based material. 50. Edible fat-based composition obtained and/or obtainable by a process, as defined in any one of clauses 1 to 35. 51. Composition, as defined in clause 50, which is a fat-based confectionery composition. 52. Composition as defined in clause 51, which is a chocolate material. 53. Composition as defined in clause 52, which is chocolate or compound. 54. Composition as defined in any one of clauses 50 to 53 having a viscosity (PV) of 2 to 6 Pa.s. 55. Composition as defined in clause 54, having a viscosity (PV) of 3 to 5 Pa.s. 56. Composition, as defined in any one of clauses 50 to 55, which has an elastic limit (YS) of 4 to 10 Pa. 57. Composition, as defined in clause 56, which has an elastic limit (YS) of 5 to 8 Pa.s. 58. A fat-based composition as defined in any one of clauses 50 to 57 that has a moisture content of at least 0.8% by weight based on the total weight of the fat-based material. 59. Chocolate or compound composition having a moisture content of at least 0.8% by weight based on the total weight of the chocolate or compound. 60. Composition as defined in either clause 58 or 59 that has a moisture content of 0.9 to 5%. 61. Composition, as defined in any one of clauses 58 to 60, which has a moisture content of 1.0% to 4.0%. 62. Composition, as defined in any one of clauses 58 to 61, which has a moisture content of 1.1% to 3.0%. 63. Composition, as defined in any one of clauses 58 to 62, which has a moisture content of 1.2% to 2.0%. 64. Composition, as defined in any one of clauses 58 to 63, which has a moisture content of 1.2% to 1.5%. 65. Use, in a sprinkling process, of an edible fat-based composition as defined in any one of clauses 50 to 64 that has a low fat content of less than 50% by weight based on the weight of the composition, the composition being prepared in the process as defined in any one of clauses 1 to 38 to have a low viscosity of 2 to 6 Pa.s. 66. A process for spraying an edible fat-based composition as defined in any one of clauses 50 to 64 onto a composition substrate that has a low fat content of less than 50% by weight based on the weight of the composition, the composition prepared in the process of the invention being to have a low viscosity of 2 to 6 Pa.s. 67. Use of a process, as defined in any one of clauses 1 to 35, for the purpose of producing an edible fat-based composition, as defined in any one of clauses 50 to 64, the composition comprising a high proportion (at least 50 parts by weight) of a desired polymorph based on 100 parts by weight being the total amount of material. 68. Use, as defined in clause 67, for the purpose of producing chocolate or compound comprising at least 60 parts by weight of a cocoa butter Polymorph of Form VI based on 100 parts by weight being the total amount of cocoa butter cocoa. 69. An edible fat-based composition as defined in any one of clauses 50 to 64 comprising a high proportion (at least 50 parts by weight) of a desired polymorph based on 100 parts by weight, the composition being prepared in the process, as defined in any one of clauses 1 to 38. 70. Edible fat-based composition, as defined in clause 69, which is chocolate or compound, comprising at least 60 parts by weight of a cocoa butter polymorph of the Form VI based on 100 parts by weight being the total amount of cocoa butter. 71. Process for preparing an edible fat-based composition as defined in any one of clauses 50 to 64 comprising a high proportion (at least 50 parts by weight) of a desired polymorph based on 100 parts by weight being the amount total composition, the process comprising steps (a) and (b) as described in any one of clauses 1 to 35 and optionally the process being free of steps comprising additional tempering and/or the addition of seed crystals. 72. Process as defined in clause 71 for preparing chocolate or compound comprising at least 60 parts by weight of a cocoa butter polymorph of Form VI based on 100 parts by weight being the total amount of cocoa butter . 73. Use of a process, as defined in any one of clauses 1 to 35, for the purpose of producing an edible fat-based composition, as defined in any one of clauses 50 to 64 or 69 or 70, the composition has better heat resistance compared to the same identically prepared fat-based composition, except that it is reduced in viscosity by a process other than that defined in any one of clauses 1 to 35. 74. Use as defined in clause 73 for the purpose of producing a composition as defined in any one of clauses 50 to 64 or 69 or 70 which has improved shape retention and/or less oil separation upon heating. 75. Edible heat resistant fat-based composition as defined in any one of clauses 50 to 64 or 69 or 70 being prepared with the process as defined in any one of clauses 1 to 35. 76. Chocolate or heat resistant compound heat, as defined in clause 75, which has improved shape retention and/or less oil separation after heating.

Claims (14)

1. Process for imparting specific work to an edible fat-based material to reduce the viscosity of the material until it reaches a predetermined target (naive) viscosity, comprising the steps of: (a) imparting a total amount of work specific work done to the fat-based edible material using an energy application medium operated by one or more control parameters, both the rate and the total amount of specific work imparted to the material being determined by one or more of the control parameters; and where the fat-based material flows through the energy application means at an instantaneous rate at a given moment in time "t" after the start of step (a) whose flow is denoted by Qt (b) controlling the means of application of energy means reaching a predetermined target viscosity (yaivo); where the rate of specific work done to the fat-based material is determined by controlling one or more of the control parameter(s) such that the specific work done by the means of energy application at a time t ' after the beginning of step (a) satisfy the relation determined in equation 1: where: (i) eta (nt) denotes the viscosity at time t' after the start of step (a) of the fat-based material measured as plastic viscosity according to the ICA 46 method (2000); (ii) omega (rat) denotes the total amount of specific work imparted to the fat-based material after time t' since the start of step (a) calculated from the power and flow rate as determined by equation (2): , where: Pt denotes the power (measured in kilowatts (kW)) imparted to the fat-based material by the energy application means at time t' after the start of step (a) Qt denotes the instantaneous flow rate (measured in kg per hour (kg/h)) of the fat-based material through the energy application means at time t' after the start of step (a); and (iii) A is from 0.5 to 0.7; and (iv) B is from 0.3 to 0.6. (c) preventing the energy application means after t = T from imparting specific work to the fat-based material, the time T being determined from equations (1) and (2) and the predetermined target viscosity (target n ), wherein the fat-based material is a chocolate material, preferably chocolate or compound, and the process is used to liquefy the chocolate material, the predetermined target viscosity (target) being liquid. 2. Process, according to claim 1, characterized in that it uses an apparatus having at least one sensor means associated with it, and being that in step (a) the sensor means measures at least one attribute of the material based on fat to generate at least one input parameter used directly or indirectly to calculate the at least one control parameter using equation (1) and optionally also equation (2). 3. Process, according to any one of the preceding claims, characterized in that the average power applied during the duration of steps (a) and (b) is denoted as Pm which is calculated from the instantaneous power measurement Pt used at several different times "t" and/or calculating the average of the total energy conferred over the total duration time "T" of step (a), and the average flow, measured in kg per hour (kg/h ), of the fat-based material through the means of application of energy released during the duration of steps (a) and (b) is denoted as Qm, which is calculated from the measurement of the instantaneous flow rate Qt used at various times "t " different, and where the total amount of specific work that needs to be imparted to the fat-based material during steps (a) and (b) to obtain the predetermined target viscosity (paivo) is denoted by w and is calculated from the equation (1A): and where the total specific work is imparted to the fat-based material during steps (a) and (b) can also be determined by equation (2A): and where the time T, which is the duration over which the energy input means imparts specific work ra to the fat-based edible material in step (a), can be determined from the Pm and/or Qm values. Process according to any one of the preceding claims, characterized in that A is from 0.5 to 0.7, preferably from 0.55 to 0.65, preferably from 0.57 to 0.61, preferably from 0.580 to 0.605, preferably from 0.5900 to 0.6000 or be from 0.592 to 3 significant figures or from 0.5919 to 4 significant figures. Process according to any one of the preceding claims, characterized in that B is from 0.3 to 0.6, preferably from 0.35 to 0.50, preferably from 0.37 to 0.50, preferably from 0.410 to 0.440, preferably from 0.4200 to 0.4300 or be from 0.427 to 3 significant figures or from 0.4268 to 4 significant figures. 6. Process according to any one of the preceding claims, characterized by reducing the viscosity of the fat-based edible material where in step (a) the work application means comprise a mixing step using a mixing means where the mixing rate is controlled by one or more of the control parameters. Process according to any one of the preceding claims, characterized by reducing the viscosity of the fat-based edible material to a target viscosity of 2 to 6 Pa.s. 8. Process according to any one of the preceding claims, characterized in that the target viscosity is 2 to 6 Pa.s and is achieved with an edible fat-based material comprising a moisture content of 0.8% to 1.5% by weight. Process according to any one of the preceding claims, characterized in that the edible fat-based material is a fat-based confectionery material, preferably a chocolate material, and preferably chocolate mass or compound mass. . 10. Process according to any one of the preceding claims, characterized in that the work rate is determined by equation (1A): 11. Process, according to any of the preceding claims, characterized in that the control parameters are defined and/or adjusted using equation (1) to optimize a selected property among: energy efficiency of the process and/or yield of the fat material through the process. 12. Process according to any one of the preceding claims, characterized in that the process additionally comprises pre-steps (D), (E) and (F) performed before steps (a) and (b) of: ( D) adding the fat-based edible material to a receptacle comprising an inlet port; and outlet port and at least one tapered interior surface provided with loosening means located on or close to it, the outlet port of the receptacle being in fluid connection with the inlet conduit of the processing chamber; (E) operating the loosening means sufficiently to loosen and/or substantially remove the fat-based material adhered to the interior surface; (F) conveying the fat-based material from the receptacle to the energy application means used in step (a) through the receptacle outlet port and the processing chamber inlet conduit. 13. Process according to any of the preceding claims, characterized in that it additionally comprises pre-steps (G) and (H) performed before steps (a) and (b) of: (G) refining the material fat-based edibles in a refiner with an outlet fluidly connected to the inlet conduit and processing chamber used in step (a), subjecting the material to at least 200,000 s-1 shear (high shear) per time sufficient to form a powdery or pasty mass, preferably a powdery mass, which is used directly in steps (a) and (b), (H) conveying the high shear refined powdery or pasty mass, preferably, the powdered mass from step (E) through the outlet and inlet conduit to the energy application means used in step (a). 14. Process according to any one of the preceding claims, characterized in that it additionally comprises pre-steps (J) and (K) performed before steps (a) and (b) of: (J) refining the material fat-based edibles having solid agglomerates therein in a refiner with an outlet fluidly connected to the inlet conduit and processing chamber used in step (a), subject the material to a maximum shear of 200,000 s-1 ( low shear) and a total mixing energy of a maximum of 1000 kW (low energy) calculated at a material flow rate of 20 kg/minute; wherein low shear, low energy mixing is carried out long enough to substantially break down the agglomerates and intimate interactions of any solids with the fat to produce a pasty or powdery mass, preferably pasty mass, in which the solids contained therein are substantially coated with fat; pasty or powdered mass, preferably pasty mass, being used directly in steps (a) and (b); and (K) conveying the refined low-shear, low-energy slurry from step (J) through the outlet and inlet conduit to the energy application means used in step (a).