CA1044944A

CA1044944A - Chocolate solid and method of manufacture

Info

Publication number: CA1044944A
Application number: CA229,181A
Authority: CA
Inventors: Brian T. Warkentin
Original assignee: Shade Foods Inc
Current assignee: Shade Foods Inc
Priority date: 1975-02-03
Filing date: 1975-06-12
Publication date: 1978-12-26
Also published as: DE2536250A1; FR2298958B3; NL7506952A; JPS5820580B2; GB1472510A; AU8105675A; FR2298958A1; JPS5191366A

Abstract

ABSTRACT OF THE DISCLOSURE

A homogeneous solid chocolate composition useful as in intermediate in producing chocolate fudge toppings and chocolate variegating sauces for ice cream is described. The composition consists essentially of 25 to 40 weight percent of cocoa determined by a fat-free basis, 30 to 40 weight percent of a mixture of a major proportion of hydrogenated vegetable oil and a minor proportion of cocoa butter, 18 to 25 weight percent of starch, 0 to 10 weight percent of low fat milk powder, 0 to 7 weight percent of sugar, 0.5 to 2.0 weight percent of lecithin and 0.5 to 3.0 weight percent of salt. Small amounts of flavor imparting materials such as vanillin may be present. The method of making the composition is described. The composition can be mixed with corn syrup, invert sugar and water, heated and subsequently cooled to provide a topping of immediate fudgy consistency. Prior art toppings conventionally require four to six weeks storage to develope a fudgy consistency.

Description

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ll .' ackground of the Invention ! Chocolate fudge toppings for ice cream are widely used confections. Currently they are manufactured.by separately adding . weighed quantities of chocolate liquor, cocoa, salt, vanillin : vegetable oil, stabilizer, emulsifier and milk powder to a measured quantity of corn syrup, sugar and water residing in a : kettle. This mixture is agitated.and heated in the kettle until ., . '.
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1l~4~9~4 an intimate mixture of all of the materials is produced. The

2 resultant intimate mixture is then packed in small bottles for

3 direct consumer use or in large cans for institutional use. Some

4 manufacturers run the mixture produced in the kettle through a

5 ¦homogenizer before packing. This method of manufacture has

6 ¦certain disadvantages. The manufacturer is required to purchase, 71 store, inventory, handle and weigh a large number of ingredients 8 ¦in formulating a kettle batch, errors are common. Unless the 9 ¦product from the kettle is run through a homogenizer before packin 10 ¦ the product is Erequently gritty due to the presence of large 11¦ particles of cocoa powder or cocoa solids in the mixture. The 12 ¦product, whether the homogenization step is used or not, is a thin 13 ¦ liquid which must be stored in the containers for as long as four 14 ¦ to six weeks before it develops the thick creamy character of an acceptable fudge topping. Immediately after packaging, it can be 16 1 poured from the container as a thin syrup, but after the four to 17 six weeks storage period, it has thickened to the point where it 18 must be spooned from the container and has all of the desired 19 characteristics of a fudge topping.
It would be desirable to simplify the manufacturing 21 -procedure for topping producers by reducing the number of ingre-22 dients which they must store, inventory and measure and it would 23 be especially desirable to enable them to avoid the four to six 24 weeks storage period required for the product to develop a thick creamy consistency so that it is in a condition suitable for sale 26 to the consumer.

28 Descrip-tion of the Invention 29 Pursuant to the present invention, a solid chocolate product is produced which can be added to corn syrup, invert sugar 31 and water, heated to elevated temperature for a few minutes to 32 form a fudge topping which can be packaged and immediately sold 1~14~99L4 1 for consumer use. The fudgy consistency appears promptly after 2 the mixture is cooled and no storage period is required for the product to develop an acceptable fudgy consistency.
4 The components of the solid chocolate composition are 5 as follows:
(a) cocoa powder or mixtures of

7 chocolate liquor and cocoa powder having

8 a fat-free cocoa content in amount to

9 constitute from 25 to 45% of the total composition. When a mixture of cocoa ll powder and chocolate liquor is used, the 12 chocolate liquor should not be used ln 13 amounts that would provide more than 30%

14 of the required fat-free cocoa. The high content of relatively low melting cocoa 16 butter in the chocolate liquor would ad-17 versely affect the softening point of the 18 final product if chocolate liquor were used 19 in larger amounts;
(b) fat consisting of a mixture of a 21 minor proportion of cocoa butter and a major 22 proportion of hydrogenated vegetable oil 23 (MP 100-110) in amount to constitu~te 30% to 2 40% by weight of the total composition. The hydrogenated vegetable oil may be any one of the common vegetable oils such as cottonseed 2 oil, soybean oil, safflower oil, sesame oil and the like, hydrogenated sufficiently to 2 bring the melting point to at least 100F.
3 The cocoa but-ter content of -the fat mixture .;, ~ 3 _.. .... . . _ . , ... , .. ._ . . _ ., _ .. ., . . ............... _.. . .. __., _. = . .. , . .,, , , , ~

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can vary within the range 10-40% by weight as the proportions of chocolate liquor and cocoa used to provide the required cocoa content are varied. When only cocoa powder (lQ-12% cOcoa butter) is used, then the cocoa butter content of the fat mixture is at the low end of the range. Increasing the proportion of chocolate liquor used raises the cocoa butter content. As noted above, the chocolate liquor should not be used to provide more than 30% of the required cocoa on a fat-free basis.
There are two reasons for holding the chocolate liquor component to this maximum level. One is economic, the chocolate liquor being considerably more expensive than cocoa; the other is technical -- the melting point of cocoa butter is about 92-94F. The presence of large amounts of cocoa but~er in the fat mixture reduces the softening point of the finished chocolate solid with the result that the relatively small pieces or wafers of solid chocolate, the most desired form for the commercial pro-duct, ~oftan and stick together forming large masses which are i difficult to measure and mix with sugar syrups.

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1 (c) starch in amount to constitute 18 2 to 25% by weight of the total composition.
3 The starch functions as a stabilizer and 4 thic~ener. The starch used may be either natural or modified starch. Thin boiling 6 starches, the hydrolyzed form of which have 7 low viscosity at around 140F. and only 8 gelatinize when cooled to about ambient 9 temperature, are preferred;
(d) low fat (Cl% at3 milk powder in 11 amount to constitute from 0 to 10% by weight 12 of the total composition;
13 (e~ sugar in amount to constitute Erom 14 0 to 7~ by weight of the total composition.
Such small amounts of sugar can be used to 16 adjust the solids content of the charge to the milling paste mixer, if desired. Such 18 amounts leave the total composition with a 19 bitter chocolate flavor, substantially unsweetened and unpalatable until mixed with 21 sugar syrup as shown in Examples, 3 and ~;
22 (f) lecithin in amount sufficient to 2 constitute from 0.5 to 2.0~ of the total 24 composition.
Desirably, but optionally, common salt in amount to 26 constitute about 0.5 to 3% by weight of the total composition and 27 vanillin in amount -to constitute about 1% of the total composition 28 are added. These two materials provide flavor but could be 2 separately added in the course of converting a composition consist 3 ing of components (a) through (f) above to a finished chocolate 33 confectlon compositlon.

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In one particular aspect the i~nvention provides a substantially unsweetened homogeneous solid chocolate composition consisting essentially of 25-40 weight pereent of cocoa determined on a fat-free basis, 30-40 weight percent of a mixture of hydrogenated vegetable oil having a melting point of at least lC)0F and cocoa butter~ said mixture containing 10-25 weight percer~t cocoa butter~
18-25 weight percent of starch, 0-10 weight percent of low-fat milk powder, 0-7 weight dpercent of sugar, 0~5-2.0 weight percent of an emulsifying agent and 0.5-3 weight percent of salt, In another aspect the invention provides a process for producing globs of a substantially unsweetened homogeneous solid chocolate composition consisting essentially of 25-40 weight percent of cocoa determined of a fat-free basls, 30-40 weight percent of a mixture of hydrogenated vegetable oil having a meltlng point of at least 100F and cocoa butter, said mixture containing 10-25 weight percent cocoa butter~ 18-25 weig~t percent of starch, 0-10 weight percent of low-fat milk powderj 0-7 weight percent of sugar, 0.5-2.0 weight percent of an emulsifying agent and 0.5-3 weight percent of salt, which comprises (1) charging the cocoa, starch~ low-fat milk powder, sugar emulsifying agent and salt components and approximately one-half of the hydrogenated vegetable oil component to a milling zone, (2) milling the mixture to form a paste, (3) passing the pase through a roll refining zone to obtain viscous paste, (4) adding the remainder of the hydrogenated vegetable oil to the effluent from the roll refining zone, ~5) heating and agitating the resultant mixture to form a homogeneous liquid, (6) raising the temperature of the liquid to a temperature in the range about 120-150 ~ and agitating it at such temperature for at least 15 minutes, and then (7) extruding small globs of the mixture not exceeding about one ounce in weight and cooling them to ambient ttemperature.

-5a_ 1044~44 1 ¦ The manufacture of the solid chocolate compositions of 2 ¦this invention are described in the following examples.

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5 ¦ Twenty-seven parts by weight of cocoa powder having a 6 ¦cocoa butter content of 11% by weight, 21 parts by weight of 7 ¦modified starch, 3.5 parts by weight of non-fat milk powder, 2 8 ¦parts by weight common salt, one part by weight vanillin and 13 9 ¦parts by weight of hydrogenated soybean oil having a melting point

10¦ 102F., 0.7 parts by weight of lecithin and 5 parts by weight of ~.

11 ¦sugar are placed in a milling paste mixer. The mixer is run unti

12¦ the mixture is ground into a paste. The paste is then passed

13¦ through five roll stainless steel refiners which ex-trude it as

14¦ a very viscous paste. This extrudate is then mixed and heated wit

15¦ an additional 13 parts by weight of hydrogenated soybean oil and

16 ¦14 parts by weight of chocolate liquor having a cocoa butter

17 ¦content of 51~ in small ribbon blenders to reduce it to a liquid

18 ¦state. The liquid is pumped into a high-speed heated mixing tank

19¦ where it is mixed and further milled. The liquid is heated to 201 140F. and held a-t tha-t tempe:rature for about 15 minu-tes during 21¦ which agitation is continued. The liquid product is then pumped 22¦ into a storage tank from which it is fed onto a moving rubber 231 conveyor belt. The depositing head squirts out small globs of 241 this liquid mixture onto a moving belt which passes through a 251 cooling tunnel where refrigerated air is circulated around it.
26¦ The globs solidify, forming wafers which are carried out of the 28 cooling tunnel and dropped into cartons. The wafers are about an l -6-!

~04g~4 1 inch in diameter and about 3/8 of an inch thick. The wafers have 2 an incipient softeniny temperature about 94-95F. and melted at 3 about lOO~F. The wafers had an average weight about 1/5 ounce.
4 They may be made larger but should not exceed about one ounce in 5 weight to facilitate weighing to close tolerances and to facili-6 tate mel-ting and mixing during their use to produce the finished 7 fudge composition.

9 Forty-two parts by weight of cocoa powder having a 10 cocoa butter content of 11% by weight, 22.6 parts by weight modi-11 fied starch, 2.9 parts by weight salt, 1 part by weight vanillin ..
12 and 15 parts by weight of hydrogenated vegetable oil having a 13 melting point 100F., and 1.~ parts by weight of lecithin were ~ charged to the milling paste mixer. After milling and passing 15 through the stainless steel refiners as in Example 1, the extrudat~
16 from the refiners was mixed with an additional 15.1 parts by 17 weight of hydrogenated vegetable oil ancl processing was continued 18 as in Example 1 to produce the wafers.
19 The total fat content, i.e., cocoa butter plus

20 hydrogenated coconut oil charged to the milling paste mixer should

21 be held in a range to constitute 15 to 25% of the total charge.

22 Holding the fat level in this range permits efficient milling and

23 mixing to achieve the desired complete homogeneity of the mix.

24 The remaining hydrogenated vegetable oil is added to the extrudate

25 from the stainless steel refiners during the final mixing step

26 which immediately precedes extrudation and cooling to produce the

27 finished wafer. If all of the fat contained in the final finished 22c8) wafer were added to the initial charge to the mill, the resulting --\

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1 mixture would be so low in viscosity that considerable difficul-ty 2 would be experienced in achieving the desired homogeneity of the 3 mixture in the milling step.

The wafers produced in Examples 1 and 2 above may be 6 used to produce the finished fudge topping composition by heating 7 15 to 20 parts by weight of corn syrup having an 86% solids 8 content, 50 to 60 parts by weight of invert sugar having a 77-789 9 solids content and 5 to 10 parts by weight of water in a mixer 10 and then addlng 10 to 15 parts by weight of the wafers to the 11 liquid. The total mixture is heated with agitation -to 190 to 12 200F. for a period of about 10 minutes during which time starch 13 hydrates. The mixture is then cooled and immediately packaged in 14 containers suitably sized for consumer use. On cooling to ambient temperature, the product is a creamy fudgy chocolate topping 16 ready for immediate consumer use. No delay is required to enable 17 the composition to develop the fudgy consistency.

19 The wafers produced in Examples 1 and 2 above can be used to produce a creamy variegating sauce of lower viscosity than 21 the fudge topping by mixing with sugar solutions having a higher 22 water content than those used in preparing the fudge topping. A
23 representative variegating sauce is obtained~by mixing 13 parts 24 by weight of -the wafers of Examples 1 or 2 with 25 parts by weight of sugar, 20 parts by weight of corn syrup solids and 42 parts by 26 weight of water and heating and agitating the mixture as in 287 Example 3.

11)4~9~4 1 ¦ Whlle hy~rogenated coconut oil has been used in the 21 above examples, other hydrogenated vegetable oils having melting 31 points above 100F. may be substituted, if desired.
4 ¦ Example 3 illustrates the use of the solid chocolate 5 ¦product of the invention in producing a chocolate fudge topping.
61 By reduciny the water content of the mixture in Example 3, a 71 chocolate fudge can be prepared by simply bringing the mixture of 8¦ chocolate wafers and syrup to the boiling point and then pouring 91 the hot mixture into a plate or pan where it sets up as a fudge.
10¦ Long cooling and testing become unnecessary.
11¦ While the foregoing exarnples have indicated the 12¦ quantities of the several components of the composition in parts 13¦ by weight, the makeup of -the composition may be expressed in terms 14 ¦of the percentage range of each component in the total composition 15 ¦as follows: 25-~0% by weight of cocoa determined on a fat-free 16 ¦basis, 30-40% by weight of a mixture of hydrogenated vegetable oil 17 ¦having a melting point about 100F. and cocoa butter, said mixture 18 ¦containing a minor proportion rom 10-25% cocoa butter, 18-25%
19 ¦by weiyht of starch, 0-10~ by weight of low-fat milk powder, 20 ¦0.5-2.0% by weight of lecithin and 0-7% by weight of suyar.
21 ¦ The compositions described herein are not suitable for 22 ¦consumption as such, but are useful intermediates for use in the ~ prepar lon of chocolate foods as descrioed.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR
PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A substantially unsweetened homogeneous solid chocolate composition consisting essentially of 25-40 weight percent of cocoa determined on a fat-free basis, 30-40 weight percent of a mixture of hydrogenated vegetable oil having a melting point of at least 100°F and cocoa butter, said mixture containing 10-25 weight percent cocoa butter, 18-25 weight percent of starch, 0-10 weight percent of low-fat milk powder, 0-7 weight percent of sugar, 0.5-2.0 weight percent of an emulsifying agent and 0.5-3 weight percent of salt.

2. A process for producing globs of a sub-stantially unsweetened homogeneous solid chocolate composition con-sisting essentially of 25-40 weight percent of cocoa determined on a fat-free basis, 30-40 weight percent of a mixture of hydrogenated vegetable oil having a melting point of at least 100°F and cocoa butter, said mixture containing 10-25 weight percent cocoa butter, 18-25 weight percent of starch, 0-10 weight percent of low-fat milk powder, 0-7 weight percent of sugar, 0.5-2.0 weight percent of an emulsifying agent and 0.5-3 weight percent of salt, which comprises (1) charging the cocoa, starch, low-fat milk powder, sugar, emulsifying agent and salt components and approximately one-half of the hydrogenated vegetable oil component to a milling zone, (2) milling the mixture to form a paste, (3) passing the paste through a roll refining zone to obtain a viscous paste, (4) adding the remainder of the hydrogenated vegetable oil to the effluent from the roll refining zone, (5) heating and agitating the resultant mixture to form a homogeneous liquid, (6) raising the temperature of the liquid to a temperature in the range about 120-150°F and agitating it at such temperature for at least 15 minutes, and then (7) extruding small globs of the mixture not exceeding about one ounce in weight and cooling them to ambient temperature.