CA1057126A

CA1057126A - Production of confectionery

Info

Publication number: CA1057126A
Application number: CA267,604A
Authority: CA
Inventors: Andrew R. Bean; George P. Greener; Robert J. Brooklyn; Ian E. Hunter
Original assignee: Mars Ltd
Current assignee: Mars Ltd
Priority date: 1975-12-12
Filing date: 1976-12-10
Publication date: 1979-06-26
Also published as: BE849316A; NL7613842A; FR2334304B1; ATA923076A; LU76373A1; DE2655757A1; CH610496A5; FR2334304A1; AT355897B; IE43784L; GB1527240A; AU2050376A; IT1067267B; DK544376A; IE43784B1; AU511660B2; JPS5272860A

Abstract

ABSTRACT OF THE DISCLOSURE

Chocolate pieces can unexpectedly be made in a tabletting press if the chocolate is in the form of particles having a mean particle size not less than 1 mm and pressing is carried out below 17°C. The process is especially suited to produce tablets with indented indicia and also pieces with other surfaces relief features. The starting material may be granules produced by milling solid chocolate and conditioning or by extrusion of chocolate powder and fragmenting spherohizing theextrudate.

Description

The present invention relates to the production of confectionery and more especially to the production of chocolate pieces having decorative or other relief featuresO
It is known in the confectionery and pharmaceutical industries to produce sweets or tablets having surface indentations such as letters or numbers from dry sugar-based compositions by the use of embossed punches or dies in a so-called tabletting press. Hitherto, however, it has not been considered practicable to produce a piece having surface relief features from a fatty material such as chocolate by a tabletting process.
Now, in accordance with this invention, there is provided a process for the production of chocolate pieces from granular solid chocolate which comprises the steps of: uniformly charging chocolate granules having a mean particle size not less than 1 mm into a tabletting die, at least 80% of the chocolate granules falling within the particle size range of 0.7 to 3.7 mm;
and compressing said granules at a forming temperature below 17C to form a piece of chocolate.
The invention is particularly suited to the production of pieces with surface relief features, which cannot be formed by the conventional moulding process. Moreover, the invention is not confined to the production 2Q of tablets with indented indicia such as letters or numbers but can be employed in the manufacture of chocolate pieces with any surface relief pattern ordesign capable of being formed in a tabletting press.

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~0571Z6 ~ he chocolate granules can be produced by milliIIg ~olid chocolate, which will normally be tempered, and the granules are preferably conditioned before introduction into the tabletting press.
Conditioning, the necessity for which decreases the narrower the particle size range of the granules, is carried out by holding the granu~es at a te~pera~ure within the range Ol 17 to 22C for redistribution of properties.
~he mass of granules being conditioned will usually be agitated because agitation greatly accelerates the conditioning prpcess.
If the granules are conditioned by rolling, this ~hould be continued for at least three minutes but there is no critical upper limit to the time of treatment. In an agitation process such as rolling it is necessar~ to use a mass of granules of sufficient depth to ensure that the passage of particles over one anoth~r aotually occur~.
An alternative way of pro~iding chocolate granules suitable for tabletting is by extrusion of "refinings" (i.e.
powdered chocolate as pbtained from a roller refiner) followed by fragmentation and spheronization of th~ fragments.
In order to obtain accepta~le throughput of material in extrusion it is preferred that the diameter of the extrudate should be at least 2mm, and to provide gramlles of the preferred size the diameter i9 pre~erabl~ not greater than 2.7 mm1 The extruded particles art~ usually 1 - 4- cm in lenKth.

~0 57 ~ Z 6 The extrudate is cooled and fed into a spheronizer, usually a cylindrical vessel in the bottom of which is a rotating grooved plate (as in that sold under the tracemark "Marumerizer:'3.
The preferred input temperature is in the range 4 - 14C but most preferably ~ - 12C. In the spheronizer t-he extrudate particles are broken up and rolled into spheres, and dust particles tend also to agglomerate into spheres. Since the ~pheronized product becomes warmed in the machiDe, for example bo 23C, the spheres are conditioned by the end of the process.
- It is noteworth~r that, in contrast to the tabletting of sugar-based compositions, it appears to be advantageous in tabletting of chocolate that fines be restricted to a low proportion. Particles of sizes of the same order as the die diameter should also be avoided. ~he usually preferred range f mean particle diameter is from 1 to 3 mm. ~herefore it is preferred that at least 85% of weight of the material shou~d lie within the particle size range of 0.7 to 3.7 mm.
~he preferred temperature for tabletting is in the range 12 - 17C, although small deviations from this range may be found practicable in some circumstances.

Formed tablets with indicia or like indented mar~ing~
can be smoothed by rolling, preferably at a temperature rather above th~ forming temperature, say about 20C, to remove the ~057~Z6 surface crazing corresponding to the individual granules.
Smoothing should, however, be halted before the indented markings are rubbed excessively.
Where appropriate, a stronger contrast between 'he marking and the chocolate can be achieved by filling indentations with powder. This may be done by rolling the formed tablets with the selected powder at a temperature rather below the smooth-ing temperature, for ex~mple about 18C. An excess Or powder over the amouht actually necessar~ to fill the indentations should be used. Examples of powdered food grade materials that may be uæed for thi~ purpose include skim or full cream milk powder, lactose, starch, pu~verized sugar or mixtures of these.
~he powder may be coloured for decorative purposes.
.

After the powder has been rolled in, the excess may be largely removed by a cool air blast and the powder filling the indentations can be sealed in by ~he addition of an a~ueous gum solution. The resulting surface provides a satisfactory base for final polishing or glazin~.
~he following is a more detailed description of two pref~rred procédures for the manufacture of chocolate sweets in accordance with the invention, given by way of example.

10571;Z6 Example 1 Solid chocolate, which has been tempered in the con-ventional way, is granulated to a mean particle size of 1.7 mm with a size distribution defined by the following weight per-centages of the granules retained by the size of screen indicated:
retained by 4 mm 0%, 2.8 mm 9.0%, 2.0 mm 35.5%, 1.7 mm 50.2%, 1.4 mm 64.4%, 1.0 mm 76.1%, 0.5 mm 93.5% (6.5% passing). The granules are then conditioned by rolling a mass of the granules 4 - 5 inches deep at a temperature of 19C for about 5 minutes.
The conditioned granules at a temperature of 13C
are supplied to a conventional tabletting press so that the dies are evenly filled with granules before pressing, the press being cooled by a supply of cool air at 10c.
After any flash or excess granules have been sieved off, the tabletted sweets are rolled in a polishing pan at a temperature of about 20C until the surface crazing disappears.
The resulting tablets may be considered satisfactory, but if a strong contrast in appearance between the relief marking and the chocolate is desired this may be achieved by filling the indentations with powder in the manner described above.

105~7~26 Example 2 Chocolate refinings are extruded at ambient tempera-ture, say about 22C to a diameter of 2.5 mm. The extrudate is cooled to 10C and fragmented and spheronized in batches in a cylindrical ~essel with a grooved plate rotating at 450 r.p.m.
for 4 minutes with an exit temperature of 23C.
The resulting spheronized material had the following particle size analysis: retained by 4 mm 0.5%; 3 mm 23.5%;

2.8 mm 42.0%; 2 mm 63%; 1.5 mm 70.5%; 1 mm 92.5%; remainder retained by 0.5 mm.
The spherical granules are tabletted as in Example 1.

1057~Z6 .. , Supplementary Disclosure ~ he tabletting process causes an increase in the temperature of the material being tabletted. Chocolate which contains a proportion of relatively low melting fats must therefore be fed into the tabletting machina below a temperature at which liquid fat production will be significant. We have -found this upper limit to be 17C. ~bove this temperature liquid fat separating from the chocolate interferes with the release of the tablets from the punches. In cases where the chocolate granules are handled in open air a low temperature limit, for example 4C, is required if condensation of water vapour on the granules is to be prevented. In a perfectly dry atmosphere successful tabletting has been carried out down to -20 C.
~he state of the chocolate ~he crystal state of the chocolate granules used for tabletting is very important in achieving a high quality tablet.
The melting properties of the chocolate fats are determined by their crystal states and the chocolate employed in the process of the invention should contain fat in the crystal state consistent with high melting point fat. This is designated the ~ form of cocoa butter. Attempts to tablet granules which contain fats in a low-melting state, namely the and ~ forms of cocoa butter, meet with the sama failure as attempts to tablet at too high a temperature. ~he "conditioniLg" process described in this specification represents one way of ensuring that the fat is in the required ~ condition, and may be contrasted with "shock cooling" of granules, which leaves the lOS71;~6 fat in an undesirable crystal state.
The type of chocolate The total fat content of the chocolate to be tabletted is an important variable and we have found that a total fat content of less than 33% is required for successful operation. Above this level, liquid fat separationoccurs as mentioned above.
Particle size distribution This is a critical factor for the production of con-sistent tablets with good, smooth surfaces and especially important where the tabletting is followed by another opera-tion such as the filling of the surface indentations. Con-trary to established practices for sugar-based tablets, a relatively wide distribution of particle sizes is required.
It is noteworthy that, in contrast to the tabletting of sugar-based compositions, it appears to be advantageous in the tabletting of chocolate that fines be restricted to a low proportion. Particles of sizes of the same order as the die diameter should also be avoided.
ln general, the mean particle size should be within the range 1 to 3 mm and at least about 80% of the particles by weight should have particle sizes in the range of about 0.7 to about 3.7 mm. For best results, however, the granules should conform to the following criteria, which have been found critical for first class tablets of high defini-tion and precision:

Mean particle size in the range 1.2-2 mm Greater than 4 mm; less than 5% (by weignt) Smaller than 0.5 mm: not less than 4~o Standard deviation of particle size distribution in the range 0 5-1.
These criteria are illustrated b~ the following tabulated experimental results.

. - ~ .
o [CIE S~ZE (mm) ¦PAR~IC1E % ARD
~ %~4.0 Yo> 2~8 %72~ 0 %~1 . 7 ~1.4 %~1.C ~ SlZ~ 0~3-3.7 mm ~
1 0.89 4.22 45.25 70.46 90.31 98.87 1.56 95.2 0.44 2 O.29 7.28 65-~9 84.29 93.94 99.17 q,70 97.0 0.38

3 0.46 2.86 ~4.56 86.51 95.38 98.99 1.66 97.4 0.30 -~ii 4 0.22 3-15 72.42 88.83 94.56 98.57 1.72 96.1 0.33 0.38 2.22 52.35 70.42 84.93 95.42 1.65 91~3 0.48 6 9.0 35.5 50.2 64.6 76.3 93.61.72 84.4 ~.85 7 5.92 22.26 41.7 46.46 65.04 91.4 1.47 79.5 .82 85-7 24.8 ~9.5 5~.2 70.0 91.2 1.53 81.3 .81 96.0 30.0 47.0 65.0 78.0 96.0 1.67 87-~ .76 1016.1 N.A. N.A. N.A. N.A. 92.96 1~83 82.~ .77 116.24 N.A. N.A. N.A. N.A. 93.49 1.67 84.3 0.59 _ . .
12 14.16 49.26 63.~2 81.79 90.11 93.64 95.37 2.78 71.7 .28 13 26.8~ 63.81 87.61 90.65 N.A. 92.22 97~.63 3.29 : 58.3 .28 14 9.79 51.73 58.84 61.83 64.72 77.14 90.21 2.28 57.2 .63 . , . . _ . ......................... . , . ., Of the ~ranule samples shown in the Table:
Experiments 1 to 5 formed tablets, but of poor surface quality;
Experiments 6 to q1 formed good tablets of high quality surface; and Experiments ~2 to 14 formed incomplete tablets owing to inadequate filling of the tabletting die.

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Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A process for the production of chocolate pieces from granular solid chocolate which comprises the steps of: uniformly charging chocolate granules having a mean particle size not less than 1 mm into a tabletting die, at least 80% of the chocolate granules falling within the particle size range of 0.7 to 3.7 mm; and compressing said granules at a forming temperature below 17°C to form a piece of chocolate.

2. A process according to Claim 1 wherein the pieces are formed at a temperature in the range 12 to 17°C.

3. A process according to Claim 1, wherein the tabletting die includes means for producing a surface relief feature and wherein the tabletted piece of chocolate has a surface relief feature thereof.

4. A process according to Claim 3, further comprising the step of:
rolling to smooth the surface of the tabletted piece of chocolate having the surface relief feature thereon at a smoothing temperature slightly above the forming temperature.

5. A process according to Claim 4 wherein the tabletted piece of chocolate is rolled at a smoothing temperature of 20°C.

6. A process according to Claim 1 wherein the tabletting die includes means for producing an indentation and wherein the tabletting piece of chocolate has an indentation therein.

7. A process according to Claim 6 further comprising the steps of:
smoothing the tabletted piece of chocolate at a smoothing temperature slightly above the forming temperature; and subsequently rolling the tabletted piece of chocolate at a temperature slightly below the smoothing temperature with an edible powder to fill the indentation therein.

8. A process according to Claim 7 wherein said tabletted piece of chocolate is smoothed at a smoothing temperature of 20°C and is filled at a temperature of 18°C.

9. A process according to Claim 1 further comprising the step of milling solid chocolate to produce chocolate granules having a mean particle size not less than 1 mm.

10. A process according to claim 9 further comprising the step of conditioning the chocolate granules at a temperature in the range of 10° to 17° C before charging the granules into the tabletting die.

11. A process according to Claim 9 further comprising the step of agitating a mass of chocolate granules at a temperature in the range of 10° to 17° C for at least 3 minutes before charging the granules into the tabletting die.

12. A process according to Claim 1 further comprising the steps of:
extruding chocolate powder;
fragmenting the extrudates; and forming the fragments into substantially spherical granules having a mean particle size not less than l mm.

13. A process according to Claim 12 wherein the steps of extruding, fragmenting and forming effect the conditioning of the chocolate.

14. A precision tabletted piece of chocolate, when produced by the process of Claim 1, 3 or 6.

Claims supported by the Supplementary Disclosure

15. A process according to Claim 1 wherein said chocolate granules contain less than 33% total fat and contain cocoa butter in the .beta. crystal state.

16. A process according to Claim 15 wherein the chocolate granules have a mean particle size in the range of 1.2 - 2 mm, wherein less than 5% by weight exceed 4 mm in size and not less than 4% are smaller than 0.5 mm, and wherein the standard deviation of particle size distribution is in the range 0.5 to 1.

17. A precision tabletted piece of chocolate, when produced by the process of Claim 15 or 16.