GB2510474A

GB2510474A - Baked edible products comprising liquid chocolate

Info

Publication number: GB2510474A
Application number: GB1321615.5A
Authority: GB
Inventors: Gunther Gaim-Marsoner; Szymon Macura; Tadeusz Klaus
Original assignee: Kraft Foods R&D Inc USA
Current assignee: Kraft Foods R&D Inc USA
Priority date: 2012-12-06
Filing date: 2013-12-06
Publication date: 2014-08-06
Anticipated expiration: 2033-12-06
Also published as: GB201321615D0; GB2510474B

Abstract

A method of manufacturing an edible product comprising chocolate comprises the steps of (a) providing a baking mixture, for example a liquid batter or a pasty mass, comprising a source of starch and a liquid chocolate; (b) baking the baking mixture in a baking apparatus; wherein the liquid chocolate provides up to 70 wt% of the baking mixture. Crunchy edible products, including wafers and extruded snack foods, such as breakfast cereals may be based on a mixture comprising liquid chocolate. Also disclosed is an edible product comprising a source starch, a sweetener, a cocoa-derived product and a fat; wherein the cocoa-derived product and the fat are evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.

Description

Chocolate Product The present invention relates to wafer and other crunchy edible products, comprising chocolate, and to methods of making said edible products.

Wafers are baked confectionery products which are thin, crisp and brittle, and are produced from a liquid batter mixture comprising flour and water or milk. Wafer batter mixtures may also contain further ingredients, which may include oil or fat, sugar, and cocoa powder. To produce a water, a batter mixture may be deposited onto a hot lower baking plate and then a hot upper baking plate is lowered onto the wafer batter mixture from above. The batter mixture is then baked between these upper and lower baking plates, for example at a temperature of 170°C for two minutes. The baked wafer is then removed from the plates.

The use of wafer batter mixtures which contain relatively high proportions of sugar and/or fat in this process may result in a baked wafer which sticks to the baking plates after baking. This sticking can disrupt an automatic baking process and can cause fouling of the baking plates.

Such fouled baking plates require cleaning before another baking operation can be carried out in order to prevent the quality of subsequently produced wafers being adversely affected.

Halting wafer production to clean the baking plates leads to a loss of production efficiency and an increase in production costs. Therefore wafers are typically produced from bailer mixtures which contain a relatively low proportion of sugar and/or fat.

A baking mixture which is more viscous than a typical batter mixture can be prepared from starch (for example from flour), and water or milk; optionally with fat or oil, and sugar. For example a pasty mass or a dough can be formed which is not pourable like a liquid bailer mixture. These baking mixtures may be used to make crunchy edible products other than wafers. For example, a pasty baking mixture can be formed in an extruder and extruded into a variety of shapes to provide crunchy snack products or breakfast cereals. The present invention relates to products of this type, as well as to wafers.

General teatures According to a first aspect of the present invention there is provided a method of manufacturing an edible product comprising chocolate, the method comprising the steps of: (a) providing a baking mixture comprising a source of starch and a liquid chocolate; (b) baking the baking mixture in a baking apparatus; wherein the liquid chocolate provides up to 70 wt% of the baking mixture.

The baking mixture may comprise at least 10 wt% of sources of starch, suitably at least wt%, for example at least 30 wt% of sources of starch. The baking mixture may comprise up to 90 wt% of sources of starch, suitably up to 80 y% for example up to 70 wt% of sources of starch.

In some embodiments the sourco of starch may be pure starch. In other embodiments it may be a product in which starch is a major part: for example at least 50 wt%, or at least 60 wt%, or at least 80 wt%, or at least 90 wt%. Other components may include fat, protein and fibre.

Suitable sources of starch include flour, for example cereal flour. Suitable types of cereal flour include wheat flour, rye flour, oat flour, barley flour, spelt flour, corn (maize) flour and rice flour; and including wheat semolina, corn (maize) semolina and rice semolina. Suitably the baking mixture comprises wheat flour.

Suitable sources of starch include flour from pea, potato, sweet potato, banana, plantain, sago, amaranth, tapioca (cassava), arrowroot, canna, cow pea, fonio, pigeon pea, cocoyam, triticale, and sorghum.

The baking mixture may contain a cereal flour and a further source of starch.

The baking mixture may comprise additional ingredients. Suitable additional ingredients include liquid oils or fats, emulsifiers, raising agents, sweeteners, milk products, flavourings, colourants and salt.

Suitable liquid fats or oils include fats or oils of plant origin; for example soybean oil, cottonseed oil, peanut oil, sunflower seed oil, rapeseed oil, olive oil, palm oU, coconut oil and palm kernel oil.

Suitable emulsifiers include vegetable lecithins and synthetic phospholipids. Suitable vegetable lecithins include soy lecithin, cottonseed lecithin and peanut lecithin.

Suitable raising agents include sodium bicarbonate and baking powder.

Suitable sweeteners include sweeteners and intense sweeteners. Suitable bulk sweeteners include sucrose, invert sugar syrup, caramel, glucose, fructose, polydextrose, high fructose corn syrup, maltodextrin, honey, maple syrup, agave syrup, jam, marmalade: stevia and sugar alcohols, for example glycerol, maltitol, isomalt, sorbitol, xylitol, lactitol, erythritol, galactitol, polyglycitol and mannitol.

The baking mixture may comprise at least 1 wt% of a bulk sweetener, suitably at least 10 wt%, for example 20 wt% of a bulk sweetener.

The baking mixture may comprise up to 65 wt% of a bulk sweetener, suitably up to 55 wt%, for example up to 45 wt% of a bulk sweetener.

Suitable intense sweeteners arc selected from, for example, aspartame, saccharin, sucralose, acesulfame-K, stevia and neohesperidine. An intense sweetener may be present in an amount of from 0.01 to 2 wt%.

Suitable milk products include milk solids and milk fat. Suitable milk solids include skimmed milk powder.

Suitable flavourings include cocoa powder, fruit concentrates, spices, hazelnut paste, orange essence, mint essence, coffee, and vanillin.

Suitably the baking mixture comprises an aqueous liquid in addition to the liquid chocolate.

Suitable aqueous liquids include water and milk.

The baking mixture may comprise at least S wt% of an aqueous liquid, suitably at least wt%, for example at least 20 wt% of an aqueous liquid.

The baking mixture may comprise up to 90 wt% of an aqueous liquid, suitably up to 80 wt%, for example up to 70 wt% of an aqueous liquid.

In some embodiments the baking mixture is a batter mixture. A batter mixture is suitably a liquid at ambient temperature of 25 C. In some embodiments the baking mixture is a baking mass. A baking mass s suitably a pasty mass or dough-like.

Step (a) involves providing a baking mixture comprising a liquid chocolate. The liquid chocolate may provide at least 5 wt% of the baking mixture, suitably at least 10 wt%, for example at least 15 wt% of the baking mixture.

The liquid chocolate may provide up to 70 wt% of the baking mixture, suitably up to 60 wt%, for example up to 50 wt% of the baking mixture.

The term chocolate in the context of the present invention is not restricted by the various definitions of chocolate provided by government and regulatory bodies.

Suitably the liquid chocolate comprises a cocoa-derived product, a fat and at least one sweetener. Suitable cocoa-derived products include low-fat cocoa solids, cocoa liquor and cocoa butter.

By low-fat cocoa solids we mean to refer to the component remaining after removal of fats from cocoa liquor.

In some embodiments the cocoa-derived product and the fat are both cocoa butter. In these embodiments the liquid chocolate comprises cocoa butter and at least one sweetener. The liquid chocolate comprising cocoa buffer may comprise an additional fat.

In some embodiments tho liquid chocolate comprises low-fat cocoa solids, a fat and at least one sweetener. Tho fat may be a single fat or a combination of more than one fat.

Suitable fats include cocoa butter and cocoa butter alternatives.

Suitable cocoa buffer alternatives include, bufferf at, a cocoa butter equivalent (CBE), a cocoa buffer replacer (CBR), a cocoa buffer substitute (CBS), (sometimes used interchangeably with CBR), a vegetable fat that is liquid at standard ambient temperature and pressure (SATP, 25t and 1 OOkPa) or any combination of the above.

CBEs are defined in Directive 2000/36/EC as complying with the following criteria: a) they are non-lauric vegetable fats, which are rich in symmetrical monounsaturated triglycerides of the type POP, POSt and StOSt; b) they are miscible in any proportion with cocoa butter, and are compatible with its physical properties (melting point and crystallisation temperature, melting rate, need for tempering phase); c) they are obtained only by the processes of refining and/or fractionation, which excludes enzymatic modification of the triglyceride structure.

Suitable CBEs include illipe, Borneo tallow, tengkawang, palm oil, sal, shea, kokum gurgi and mango kernel or synthetic CBEs such as COBERINE (RTM) produced by Loders Croklaan, The Netherlands. CBEs may be used in combination with cocoa butter.

Suitable CBSs (or CBRs) include CBS laurics and CBS non-laurics. CBS laurics are short-chain faffy acid glycerides. Their physical properties vary but they all have triglyceride configurations that make them compatible with cocoa buffer. Suitable CBSs include those based on palm kernel oil and coconut oil. CBS non-laurics consist of fractions obtained from hydrogenated oils. The oils are selectively hydrogenated with the formation of trans acids, which increases the solid phase of the fat. Suitable sources for CBS non-laurics include soya, cottonseed, peanut, rapeseed and corn (maize) oil.

Suitable vegetable fats are liquid at standard ambient temperature and pressure (SATP, 25°C and lOOkPa). A liquid vegetable fat may be employed when a liquid chocolate composition is desired. Suitable vegetable fats include corn oil, cotton seed oil, rapeseed oil, palm oil, safflower oil, and sunflower oil.

The present invention is further applicable to compositions in which some or all of the fat is constituted by a partly or wholly non-metabolisable fat, for example Caprenin or Olestra.

"Chocolate" in the context of the present invention includes dark, milk, white, compound chocolate and any other confectionery mass which is solid at ambient temperature and contains fat (o.g. cocoa butter or cocoa butter alternative) and one or more components derived from cocoa beans (e.g. cocoa powder). A sweetener (e.g. sucrose) is typically also contained in the chocolate. Other optional components include milk components (e.g. milk fat and milk powder).

The liquid chocolate may comprise at least 1 wt% low-fat cocoa solids, suitably at least 5 wt%, for example at least 8 wt% low-fat cocoa solids.

The liquid chocolate may comprise up to 30 wt% low-fat cocoa solids, suitably up to 20 wt%, for example up to 15 wt% low-fat cocoa solids.

The liquid chocolate may comprise at least 10 wt% of a fat, suitably at least 20 wt%, for example at least 30 wt% of a fat.

The liquid chocolate may comprise up to 70 wt% of a fat, suitably up to 60 wt%, for example up to 50 wt% of a fat.

The low-fat cocoa solids and fat together may provide at least 20 wt% of the liquid chocolate, suitably at least 30 wt%, for example at least 40 wt%.

The low-fat cocoa solids and fat together may provide up to 90 wt% of the liquid chocolate, suitably up to 80 wt%, for example up to 70 wt%.

Suitably the fat comprised in the liquid chocolate is cocoa butter.

Suitably the liquid chocolate comprises cocoa liquor. Cocoa liquor comprises low-fat cocoa solids and cocoa butter. The liquid chocolate may comprise cocoa liquor and an additional fat.

Suitable additional fats are as described above in relation to the fat. Suitably the liquid chocolate comprises cocoa liquor and additonal cocoa butter.

The liquid chocolate may comprise at least one sweetener. The at least one sweetener may be a bulk sweetener or an intense sweetener. Suitable bulk sweeteners include sucrose, invert sugar syrup, caramel, glucose, fructose, polydextrose, high fructose corn syrup, maltodextrin, honey, maple syrup, agave syrup, jam, marmalade, stevia and sugar alcohols, for example glycerol, maltitol, isomalt, sorbitol, xylitol, lactitol, erythritol, galactitol, polyglycitol and mannitol.

The liquid chocolate may comprise at least 1 wt% of a bulk sweetener, suitably at least 10 wt%, for example 20 wt% of a bulk sweetener.

The liquid chocolate may comprise up to 70 wt% of a bulk sweetener, suitably up to 60 wt%, for example up to 55 wt% of a bulk sweetener.

Tho liquid chocolato may compriso at loast ono intonsc swcotonor, for oxamplo to altor the flavour or roduco the calorio valuc of the odiblo material. Suitablo intense swootonors arc selected from, for example, aspartame, saccharin, sucralose, acesulfame-K, stevia and noohosporidino. An intonso swootonor may bo prosont in an amount of from 0.01 to 2 wt%.

The liquid chocolate may comprise additonal ingredients. Suitable additional ingredients include milk products, emulsifiers and flavourings.

Suitable milk products include milk solids and milk fat. Suitable milk solids include skimmed milk powdor.

Suitable flavourings include hazelnut paste, orange essence, mint essence, lemon grass, coriandor, cinnamon, gingor, coffoo, and vanillin.

Tho liquid chocolato may bo providod as a solid chocolato composition which is subsoquontly moltod in tho baking mixturo to provido a baking mixturo comprising a liquid chocolatc.

Step (b) involves baking the baking mixture in a baking apparatus. Suitable baking apparatus include baking platos, oxtrudors, ovens, wafer-roll ovons, microwave ovons, infrarod ovens and any combination thoroof (so callcd hybrid ovcns).

According to a socond aspoct of tho prosont invontion there is providod an odiblo product formed from a baking mixture comprising a source of starch and a liquid chocolate.

The suitable features of the baking mixture described in relation to the first aspect apply to the baking mixture of this second aspect.

Suitably the odiblo product of this socond aspcct is formod by a method according to the first aspect.

According to a third aspoct of the prosont invcntion there is provided an edible product comprising a source of starch and a chocolate; wherein the chocolate is evenly distributed throughout a self-supporting, preferably crisp, matrix comprising cooked starch.

According to a fourth aspect of the present invention there is provided an edible product comprising a sourco of starch, a swootoner, a cocoa-dorivod product and a fat; whoroin the cocoa-dorivod product and the fat aro cvcnly distributed throughout a sclf-supporting, preferably crisp, matrix of cooked starch. Suitable cocoa-derived products, fats, sweeteners and starches are as described in relation to the first aspect.

In some embodiments the edible product comprises a source of starch, a sweetener, low-fat cocoa solids and a fat; wherein the low-fat cocoa solids and the fat are evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.

Suitablo fats include cocoa buttor and cocoa buttor altornativos. Tho suitablo cocoa buttor altornativos doscribod in rolation to tho first aspoct apply to the cocoa buttor altornativos of this fourth aspect.

In some embodiments the cocoa-derived product and the fat are both cocoa butter. In these embodiments the edible product comprises a source of starch, a sweetener and cocoa butter; wherein the cocoa butter is evenly distributed throughout a self-supporting, preferably crisp, matrix of cookod starch.

Embodiments of tho invontion may provide a chocolato wafor product, a chocolate wafor-roll product or an oxtrudod chocolato product, as will now bo soparatoly dofinod and doscribod.

Chocolate Wafer Product According to a fifth aspect of tho prosont invontion thoro is provided a mothod of manufacturing an odiblo product comprising chocolato, the mothod comprising tho stops of: (a) providing a batter mixture comprising a flour and a liquid; (b) mixing a liquid chocolate with the batter mixture to provide a chocolate batter mixture; (c) baking tho chocolato battor mixture in a baking apparatus; wherein the liquid chocolate provides from 5 to 50 wt% of the chocolate batter mixture.

Tho odiblo product is suitably a chocolate wafor product.

Suitably tho batter mixturo is a liquid. Suitably the battor mixturo is pourablo; for oxamplo it will flow under its own weight when poured from a vessel at ambient temperature of 25°C. The addition of liquid chocolate to the batter mixture provides a chocolate batter mixture. Suitably the chocolate batter mixture is a liquid. Suitably the chocolate batter mixture is pourable; for example it will flow under its own weight when poured from a vessel at ambient temperature of 25CC.

Suitablo typos of flour includo coroal flour; for oxamplo whoat flour, oat flour, barloy flour, spolt flour, ryo flour, corn (maizo) flour and rico flour. Suitably tho battor mixturo comprises whoat flour.

Tho batter mixturo may comprise at least 10 wt% flour, suitably at loast 20 wt%, for oxamplo at least 30 wt% flour.

The batter mixture may comprise up to 70 wt% flour, suitably up to 60 wt%, for example up to 50 wt% flour.

The batter mixture may contain an additional starch. Suitable starches include starches derived from pea, potato, sweet potato, banana, sago, amaranth, tapioca (cassava), arrowroot, canna, cow pea, fonio, cocoyam, triticale, and sorghum.

The batter mixture may comprise from 1 wt% to 15 wt% of an additional starch, suitably from 1 wt% to i 0 wt%, for example from 1 wt% to 5 wt% of an additional starch.

Suitable liquid fats or oils, emulsifiers, raising agents, milk products and fiavourings are as described in relation to the baking mixture of the first aspect.

Suitable sweeteners include sweeteners and intense sweeteners. Suitable bulk sweeteners are as defined in relation to the first aspect.

The batter mixture may comprise up to 40 wt% bulk sweetener, suitably up to 30 wt%, for example up to 20 wt% bulk sweetener.

The batter mixture may comprise at least I wt% bulk sweetener, suitably at least Swt% bulk sweetener, for example at least 10 wt% bulk sweetener.

Suitable intense sweeteners are selected from, for example, aspartame, saccharin, sucralose, acesulfame-K, stevia and neohesperidine. An intense sweetener may be present in an amount of from 0.01 to 2 wt%.

Suitably the batter mixture comprises an aqueous liquid. Suitable aqueous liquids include water and milk.

The batter mixture may comprise at least 30 wt% of an aqueous liquid, suitably at least wt%, for example at least 50 wt% of an aqueous liquid.

The batter mixture may comprise up to 90 wt% of an aqueous liquid, suitably up to 80 wt%, for example up to 70 wt% of an aqueous liquid.

Step (b) involves mixing a liquid chocolate with the batter mixture. The liquid chocolate may provide at least 5 wt% of the batter mixture, suitably at least 10 wt%, for example at least I 5 wt% of the batter mixture.

The liquid chocolate may provide up to SO wt% of the batter mixture, suitably up to 40 wt%, for example up toSS wt% of the batter mixture.

Suitable features of the liquid chocolate are as defined in relation to the first aspect.

The chocolate battor mixture may comprise a bulk sweotener. The bulk sweetener may be provided in the batter mixture. The bulk sweetener may be provided in the liquid chocolate.

The bulk sweetener may be provided in both the batter mixture and the liquid chocolate.

The chocolate batter mixture may comprse up to 40 wt% bulk sweetener, suitably up to 30 wt%, for example up to 20 wt% bulk sweetener.

The chocolate batter mixture may comprise at least 1 wt% bulk sweetener, suitably at least wt% bulk sweetener, for example at least 10 wt% bulk sweetener.

Suitably step (c) comprises depositing the chocolate batter mixture onto a baking plate and baking the chocolate batter mixture. Suitably a second baking plate is lowered onto the first baking plate comprising the chocolate batter mixture such that the chocolate batter mixture is baked between the two baking plates. Suitably step (c) comprises baking the chocolate batter mixture between two baking plates. Suitably the baking plates are at temperatures in the range 140°C to 220°C during baking, for example in the range 150°C to 200°C, suitably in the range 160°C to 180°C.

The baking plates may be substantially flat and provide a substantially flat chocolate wafer.

Alternatively the baking plates may be shaped to provide a chocolate wafer which is not substantially flat, for example a chocolate wafer shell. The shaped baking plates may comprise upper and lower baking plates with complimentary shapes which when brought together in use provide a gap for receiving and cooking the chocolate batter mixture. The chocolate batter mixture may be deposited onto a shaped lower baking plate and an upper baking plate with a complimentary shape to the lower baking plate may be lowered onto the chocolate batter mixture. As the upper baking plate contacts and starts to cook the chocolate batter mixture, the chocolate batter mixture is forced through the gap between the baking plates and therefore takes the shape of the gap, for example a shell.

After baking the baking plates may be separated and the chocolate wafer product removed.

Suitably the chocolate wafer product is removed by passing air through air nozzles arranged on the baking surfaces of the baking plates such that the air passing through the nozzle exerts a force on the chocolate wafer product causing it to lift off the baking the plates.

Baking the chocolate batter mixture between two baking plates may provide a chocolate wafer.

The chocolate wafer provided by the method of this aspect of the present invention may be thin, crisp and brittle. In addition to the thin, crisp and brittle characteristics typical of conventional wafers, the chocolate wafers provided by this aspect may provide a chocolate taste to a consumer which is not provided by conventional wafers. The taste of the chocolate wafers provided by this aspect may be different to the taste of known wafers which comprise cocoa powder.

Suitably a chocolato wafer has an avorago thicknoss not groatcr than 5 mm. Suitably tho chocolato wafer has an avorago thicknoss of from 1.5 to 3.0 mm.

Tho method of this aspoct may provido a chocolate wafer which can bo oasily romovod from the baking plates. Suitably the chocolate wafer does not stick or burn onto the baking plates at the baking temperatures between 140°C to 220°C during baking, for example between 150°C to 200°C, suitably between 160°C to 180°C.

The method of this aspect may provide chocolate wafers which are less brittle than conventional wafors producod from a batter mixturo which doos not contain liquid chocolato.

Tho chocolato wafers may bo loss moisturo sonsitivo than convontional wafors and therefore have a longer shelf-life than conventional wafers.

Suitably tho chocolato wafor product doos not molt whon handlod by a consumor.

According to a sixth aspoct of tho prosont invcntion thorc is provided an odiblo product formod from a battor mixturc comprising flour, a liquid and a liquid chocolato.

The suitable features of the batter mixture, the chocolate and the edible product described in rolation to tho fifth aspect apply to tho batter mixture, thc chocolate and the cdiblc product of this sixth aspect.

Suitably the edible product is a chocolate wafer product.

Suitably the edible product of this sixth aspect is formed by a method according to the fifth aspect.

According to a sovonth aspoct of the prosont invention there is providod an odiblo product comprising a flour and a chocolate; whercn the chocolatc is evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.

Suitably the edible product is a chocolate wafer product.

According to an eighth aspoct of tho prosont invontion thorc is provided an odiblo product comprising a flour, a sweetener, a cocoa-derived product and a fat; wherein the cocoa-derived product and tho fat arc ovonly distributod throughout a self-supporting, proforably crisp, matrix of cooked starch. Suitablo cocoa-dorivcd products, fats, swcotoncrs and starchos arc as described in relation to the fifth aspect.

Suitably tho odiblc product is a chocolato wafer product.

In somo ombodimonts tho odiblo product compriscs a flour, a swootonor, low-fat cocoa solids and a fat; wheroin tho low-fat cocoa solids and the fat arc ovonly distributod throughout a self-supporting, preferably crisp, matrix of cooked starch.

Suitablo fats include cocoa buttor and cocoa buttor altornativos. Tho suitablo cocoa buttor altornativos doscribod in rolation to tho fifth aspoct apply to the cocoa buttor altornativos of this eighth aspect.

In some embodiments the cocoa-derived product and the fat are both cocoa butter. In these embodiments the edible product comprises a flour, a sweetener and cocoa butter; wherein the cocoa butter is evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.

Tho suitablo foaturos of the chocolate wafor product doscribod in rolation to tho fifth aspoct apply to tho sixth, sovonth and oighth aspects.

Chocolate Wafer-roll Product According to a ninth aspcct of tho prcscnt invontion thoro is provided a mothod of manufacturing an odiblo product comprising chocolato, tho mothod comprising tho stops of: (i) providing a batter mixture comprising flour and a liquid; (U) mixing a liquid chocolate with the batter mixture to provide a chocolate batter mixture; (Hi) baking tho chocolato battor mixture in a baking apparatus; wherein the liquid chocolate provides from 5 to 70 wt% of the chocolate batter mixture.

Tho odiblo product is suitably a chocolato wafor-roll product.

Tho battor mixturo may comprise at least 10 wt% flour, suitably at Icast 15 wt%, for oxamplo at least 20 wt% flour.

The batter mixture may comprise up to 50 wt% flour, suitably up to 40 wt%. In some embodiments it may comprise up to 30 wt% flour.

In some embodiments the batter mixture comprises from 25 to 40 wt% flour.

The batter mixture may comprise up to 65 wt% bulk sweetener, suitably up to 55 wt%, for example up to 45 wt% bulk sweetener.

The batter mixture may comprise at least 5 wt% bulk sweetener, suitably at least I OwtS bulk sweetener. In some embodiments the batter mixture may comprise at least 15 wt% bulk sweetener, for example at least 25 wt% bulk sweetener.

The batter mixture may comprise at least 30 wt% of an aqueous liquid, suitably at least 40 wt%, for example at least 50 wt% of an aqueous liquid.

Step (ii) involves mixing a liquid chocolate with the batter mixture to provide a chocolate batter mixture. The liquid chocolate provides at least 5 wt% of the chocolate batter mixture, suitably at least 10 wt%, for example at least 15 wt%. The liquid chocolate may provide at least wt% of the chocolate batter mixture, suitably at least 30 wt%, for example at least 40 wt% of the chocolate batter mixture.

Tho liquid chocolato may provido up to 70 wt% of tho chocolato battor mixture, suitably up to wt%, for oxamplo up to 50 wt% of thc chocolato battor mixturo.

Suitable features of thc liquid chocolate arc as dofinod in rolation to tho first aspcct.

Tho chocolato battor mixturo may compriso a bulk swootonor. Thc bulk swootonor may be providod in tho batter mixturo. Tho bulk swoctonor may bo providod in tho liquid chocolato.

The chocolate batter mixture may comprse up to 65 wt% bulk sweetener, suitably up to wt%, for example up to 45 wt% bulk sweetener.

Tho chocolato batter mixturo may compriso at loast 5 wt% bulk swootener, suitably at loast 10 wt% bulk sweetener, for example at least lbwt% bulk sweetener. In some embodiments the chocolato battor mixture may compriso at least 25 wt% bulk swootonor.

Step (Hi) may comprise baking the chocolate batter mixture in a wafer-roll baking apparatus.

Typical wafer-roll baking apparatus comprise a heated drum. The chocolate batter mixture is dopositcd onto tho heatod insido surfaco of tho drum as it rotatos. Tho dopositod chocolate bailer mixturo cooks during a rotation of thc hoated drum, typically during 45 soconds to 2 minutes, to provide a chocolate wafer in a semi-plastic state. At the end of a rotation of the drum tho chocolate wafer is stripped off tho insido surface of tho drum, rollod into a tuba and thon cut to tho roquirod lcngth to provido the chocolato wafcr-roll product.

The chocolate wafer-rolls may be subsequently filled and/or coated. Suitable fillings include croam basod fillings or jolly fillings. Suitable coatings include chocolato coatings. Thc coating may include edible granular material. Suitable edible granular material include nuts, nut pieces, chocolate, dried fruit, dried vegetables, grains, biscuit (cookie' in US terminology), cake and wafer.

Tho mothod of this ninth aspoct may provide chocolato wafer-rolls which are loss brittle than conventional water-rolls produced from a batter mixture which does not contain liquid chocolato. Tho chocolato wafor-roll may bo loss moisture sonsitivo than convontional wafor-rolls and thoroforo have a longcr sholf-lifo than convontional wafer-rolls.

Suitably the chocolato wafor-roll product doos not molt whon handlod by a consumor.

Suitably tho chocolate wafor-roll product provides a consumer with an improvod chocolate tasto compared with known wafor-roll products which comprise cocoa powdor as a flavouring.

The chocolate wafer-roll product provided by this first embodiment is suitably semi-plastic immodiately aftor baking and sots hard aftor a short period of timo to provido a sclf-supporting, preferably crisp, and brittle chocolate wafer-roll.

According to a tonth aspoct of tho prosont invontion thoro is providod a chocolato wafor-roll product formod from a battor mixturc comprising flour, a liquid and a liquid chocolato.

Tho suitablo foaturos of tho batter mixture, the chocolate and tho chocolate wafor-roll described in relation to the ninth aspect apply to the batter mixture, the chocolate and the chocolate wafer-roll of this tenth aspect.

Suitably the chocolate wafer-roll product of this tenth aspect is formed by a method according to tho ninth aspoct.

The amounts of liquid chocolate present in the chocolate batter mixture as defined in relation to the ninth aspect. It will be appreciated that the baked chocolate wafer-roll product contains much lower lovols of liquid.

Suitably tho chocolato wafor-roll product comprisos loss than 10 wt% moisturo, for oxamplo loss than 5 wt%, or loss than 1 wt%.

The chocolate wafer-roll product may comprise at least 10 wt% chocolate, suitably at least 20 wt%, for oxamplo at Icast 25 wt% or at loast 30 wt%.

The chocolate wafer-roll product may comprise up to 80 wt% chocolate, suitably up to 70 wt%, br oxamplo up to 60 wt% or up to 55 wt%.

According to an olovonth aspoct of tho prosont invention thoro is providod a chocolate wafor-roll product comprising flour and a chocolate; wherein the chocolate is evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.

According to a twolfth aspect of the present invontion thoro is providod a chocolato wafor-roll product comprising a flour, a swoctonor, a cocoa-dcrivcd product and a fat; wherein tho cocoa-derived product and the fat are evenly distributed throughout a self-supporting, proforably crisp, matrix of cookcd starch. Suitablo cocoa-dorivod products, fats, swootonors and starchos arc as doscribod in relation to the first aspoct.

In some embodiments the chocolate water-roll product comprises a flour, a sweetener, low-fat cocoa solids and a fat; whcroin tho low-fat cocoa solids and tho fat arc ovonly distributod throughout a self-supporting, preferably crisp, matrix of cooked starch.

Suitable fats include cocoa butter and cocoa butter alternatives. The suitable cocoa butter alternatives described in relation to the first aspect apply to the cocoa butter alternatives of this twelfth aspect.

In some embodiments the cocoa-derived product and the fat are both cocoa butter. In these embodiments the chocolate water-roll product comprises a flour, a sweetener and cocoa buffer; wherein the cocoa butter is evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.

The suitable features of the chocolate wafer-roll product described in relation to the ninth aspect apply to the tenth, eleventh and twelfth aspects.

Extruded Chocolate Product According to a thirteenth aspect of the present invention there is provided a method of manufacturing an edible product comprising chocolate, the method comprising the steps of: (1) providing a baking mass comprising a source of starch; (2) mixing a liquid chocolate with the baking mass to provide a chocolate baking mass; (3) extruding the chocolate baking mass; wherein the liquid chocolate provides up to 20 wt% of the chocolate baking mass.

Suitably the baking mass is a pasty mass, for example a dough. Suitably the pasty mass or dough is not a pourable liquid like a baffer mixture. The pasty mass or dough may be a plastic body, changing its shape under an applied stress by undergoing a plastic deformation. The pasty mass or dough may not flow or flow only very slowly under its own weight, for example when a vessel containing the pasty mass is tipped onto its side or turned upside down.

However the dough or pasty mass is formable, for example it can be worked into a particular shape. For example the dough is extrudable by a suitable extrusion means. The dough or pasty mass may be deposited or spread onto a surface. When worked into a particular shape, extruded or deposited, the pasty mass may substantially retain the shape produced by that process.

Suitably the baking mass is formed by charging an extruder with a source of starch and other ingredients, if present. The baking mass may be formed by charging an extruder with dry ingredients, for example starches, cereal grains, flour, milk powder, whey powder, sugar and raising agents; and with liquid or semi-liquid ingredients, for example liquid oils or fats, emulsifiers, water, milk, liquid chocolate, caramel, syrups and honey.

Suitable sources of starch include flour from pea, potato, sweet potato, banana, plantain, sago, amaranth, tapioca (cassava), arrowroot, canna, cow pea, fonio, pigeon poa, cocoyam, triticale, and sorghum.

The baking mass may comprise more than one source of starch. The baking mass may comprise at least 40 wr/0 of sources of starch, suitably at least 50 wt%, for example at least wt% of sources of starch. The baking mass may comprise up to 90 wt% of sources of starch, suitably up to 80 wt%, for example up to 70 wt% of sources of starch.

Suitably the baking mass comprises flour. The baking mass may comprise from 1 to 20 wt% flour, suitably from 1 to 15 wt% flour, for example from 5 to 15 wt% flour. Suitably the flour is wheat flour.

The baking mass may comprise additional ingredients. Suitable additional ingredients include liquid oils or fats, emulsifiers, raising agents, sweeteners, milk products and salt.

Suitable liquid fats or oils, emulsifiers, raising agents and milk products are as described in relation to the baking mixture of the first aspect.

The baking mass may comprise up to 50 wt% bulk sweetener, suitably up to 40 wt%, for example up to 30 wt% bulk sweetener.

The baking mass may comprise at least 1 wt% bulk sweetener, suitably at least 5 wt% bulk sweetener, for example at least 10 wt% bulk sweetener.

In some embodiments the baking mass comprises an aqueous liquid. Suitable aqueous liquids include water and milk.

The baking mass may comprise at least 5 wt% of an aqueous liquid, suitably at least 10 wt%, for example at least 15 wt% of an aqueous iquid.

The baking mass may comprise up to 35 wt% of an aqueous liquid, suitably up to 30 wt%, for example up to 25 wt% of an aqueous liquid.

In some embodiments the baking mass does not comprise an aqueous liquid.

Stop (2) involves mixing a liquid chocolate with the baking mass. The liquid chocolate may provide from 5 to 20 wt% of the baking mass, suitably from 5 to 17 wt%, for example from 5 to wt% of the baking mass.

The chocolate baking mass may comprise a bulk sweetener. The bulk sweetener may be provided in the baking mass. The bulk sweetener may be provided in the liquid chocolate.

The bulk sweetener may be provided in both the baking mass and the liquid chocolate.

The chocolate baking mass may comprise up to 50 wt% bulk sweetener, suitably up to wt%, for example up to 30 wt% bulk sweetener.

The chocolate baking mass may comprise at least I wt% bulk sweetener. suitably at least wt% bulk sweetener, for example at least 10 wt% bulk sweetener.

The baking mass may be formed from dry ingredients under pressure and at a temperature higher than room temperature, for example within an extruder.

Step (2) may involve introducing a solid chocolate to the baking mass which is then melted by raising the temperature of the baking mass, for example in an extruder.

Steps (I) and (2) may involve adding a source of starch and a solid chocolate to an extruder which then melts the chocolate and mixes the chocolate with the source of starch to provide a baking mass comprising liquid chocolate.

Step (3) may be carried out using an extruder. Suitable extruders include a twin-screw extruder, a cooker-extruder, a planetary extruder and a co-extruder.

Suitably step (3) cooks and expands the chocolate baking mass to provide an edible product.

Step (3) may be carried out using a co-extruder. Suitably a co-extruder comprises a centre pipe for extruding a second material and can provide an edible product which comprises an enclosed cavity. The enclosed cavity may be filled with air or an edible filling. Suitable edible fillings include nut pastes, chocolate, chocolate derivatives, fruit pastes, cake, vegetable pastes, jam, marmalade, nougatine, truffle, frangipane, buttercream filling, cheese, cream or other soft cheese filling and caramel.

Suitably in step (3) the baking mass is co-extruded with a filling to provide an edible product comprising the filling in an enclosed cavity.

The method of this thirteenth aspect may provide a crunchy chocolate product. Suitably the crunchy chocolate product is crisp and brittle but is not thin like a typical wafer.

Suitably the crunchy chocolate product providos a consumer with an improved chocolate taste compared with known crunchy products which compriso cocoa powder as a flavouring.

The edible products produced by the method of this thirteenth aspect, for example crunchy chocolate products, may have one or more improved properties compared with typical chocolate containing products. For example the edible products are suitably more resistant to heat than typical chocolate products. For example the edible products do not melt when handled by a consumer and/or do not partially melt and coalesce when multiple edible products are packaged together without indvidual wrapping.

According to a fourteenth aspect of the present invention there is provided an edible product formed from a baking mass comprising a source of starch and a liquid chocolate.

The suitable features of the baking mass, the chocolate and the edible product described in relation to the thirteenth aspect apply to the baking mass, the chocolate and the edible product of this fourteenth aspect.

Suitably the edible product of this fourteenth aspect is formed by a method according to the thirteenth aspect.

According to a fifteenth aspect of the present invention there is provided an edible product comprising a source of starch and a chocolate; wherein the chocolate is evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.

According to a sixteenth aspect of the present invention there is provided an edible product comprising a source of starch, a sweetener, a cocoa-derived product and a fat; wherein the cocoa-derived product and the fat are evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch. Suitable cocoa-derived products, fats, sweeteners and starches are as described in relation to the first aspect.

Suitable fats include cocoa butter and cocoa butter alternatives. The suitable cocoa butter alternatives described in relation to the first aspect apply to the cocoa butter alternatives of this sixteenth aspect.

In some embodiments the cocoa-derived product and the fat are both cocoa butter. In these embodiments the edible product comprises a source of starch, a sweetener and cocoa butter; wherein the cocoa butter is evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.

Tho suitablo foaturos of tho odiblo product doscribod in rolation to the thirtoonth aspect apply to tho fourtoonth, fiftocnth and sixtecnth aspects.

ExamDlo 1 -Production of Chocolato Wafor Tablo I -Batter Mixturo Composition ________________ wt% Water 59 Flour 40 Rapeseed oil 1 Soy lecithin <1 Salt <1 Sodium bicarbonate <1 770g total The ingredients in Table 1 were mixed to provide a smooth liquid batter mixture.

Table 2-Liquid Chocolate Composition ________________ wt% Crystal sugar 47 Cocoa butter 17 Skimmed milk powder 19 Cocoa liquor 10 Milk fat 5 Hazelnut_paste ____________ Soy_lecithin __________ Vanillin ci 230g total Tho liquid chocolatc (230g) comprising the ingredionts listed in Tablc 2 woro addod to the liquid batter mixture (770g) and mixed to provide a chocolate batter mixture. The chocolate batter mixture was deposited onto a lower baking plate having a temperature of 170 °C and an upper baking plate having a temperature of 170 °C was lowered onto the chocolate batter mixturo. Tho chocolato battor mixturo was bakcd botwoon tho uppor and lower baking platos for 120 seconds. Tho uppor baking plate was thon raisod and tho chocolate wafor product removed from The lower baking plate. The chocolate wafer product was semi-plastic immodiatoly aftor baking and sot hard aftor several seconds to provido a rigid (ic. solf-supporting) and crunchy chocolato wafor.

Example 2 -production ol chocolate wafer-roll Qroduct A liquid chocolate was provided comprising the following ingredients: Table 3-Liquid Chocolate Composition

MILK CHOCOLATE MASS

FORMULA MI0 SUGAR 45,71 SKIMMED MILK POWDER 12,91 WHEY POWDER 4,75 ANHYDROUS MILK FAT 4,70 COCOA BUTTER DEODORISED 17,29 COCOA MASS (LIQUOR) 14,12 SOY LECITHIN 0,53 VANILLIN 0,01 Total fat content [%] 30,60 Moisture content [%] max. 1,00 Cocoa solids content [%] 32,00 A batter mixture was formed by mixing water with sugar and salt, then adding fructose syrup, lecithin and wafer flour. The liquid chocolate was added and the mixture mixed for 150 seconds and then 30 seconds. The water temperature was 22C. Prior to dosing the chocolate was melted and held in a warming cabinet at 45C for 12 hours. The following mixtures were prepared:

Table4

COMPOSITION 1 2 3 4 5 [g] dry [g] dry [I dry [I dry [g] dry Ingredient mass mass mass mass mass _________________ _______ [g] _____ [ni _____ [I _____ [g] _______ [] Water 158 0 158 0 158 0 158 0 158 0 Sugar 20,00 20 25,0 25 30,0 30 35,0 35 40,00 40 _________ ___ ___ 0 ___ 0 ____ 0 ___ ___ ___ High Fructose Syrup 6,00 4,31 6,00 4,31 6,00 4,31 6,00 4,31 6,00 4,31 Salt 0,70 0,7 0,70 0,7 0,70 0,70 0,70 0,70 0,70 0,70 CocoaPowder 0 0 0 0 0 0 0 0 0 0 Alkalized ________ _______ ______ _______ _____ _________ ______ ________ ________ ________ Wheat Flour 100 84,5 100 84,5 100 84,5 100 84,5 100 84,5 RapeSeedOil 0 0 0 0 0 0 0 0 0 0 MILK 110 108,9 100 99 90 89,1 80 79,2 70 69,3

CHOCOLATE ______ _____ ____ _____ ____ ______ _____ ______ ______ ______

%of chocolate per 110 100 90 80 70 wheat flour _______ ______ _____ ______ _____ ________ ______ _______ _______ _______ % of chocolate per 50 46 43 39 35 dry mass of wafer _______ ______ _____ ______ _____ ________ ______ _______ _______ _______ The chocolate batter mixtures obtained had a temperature of between 27.5 and 28.5C. this mixturo was dosod on a baking-tray using a confoctioncry syringo and baked at 18O-19OC for 300 seconds.

Aftor baking tho floxiblo dough strips woro wound ovor rotating mandrols to provido tho dosirod chocolate water-roll product.

All of the tested compositions provided a homogeneous mixture and were easily released from the baking plate. However the best results were obtained using compositions 4 and 5.

Photographs of products obtained from these examples are shown in Fig IA (composition 4) and Fig lB (composition 5).

Claims

CLAIMSI. A method of manufacturing an edible product comprising chocolate, the method comprising tho stops of: (a) providing a baking mixture comprising a source of starch and a liquid chocolate; (b) baking the baking mixture in a baking apparatus; wherein the liquid chocolate provides up to 70 wt% of the baking mixture.
2. The method according to claim 1 wherein the liquid chocolate provides at least 5 wt% of the baking mixture
3. Tho mothod according to claims 1 or 2 whoroin tho liquid chocolato comprisos a cocoa-derived product, a fat and at least one sweetener.
4. Tho mothod according to any procoding claim whoroin tho baking mixturo comprisos at least 10 wt% of sources of starch.
5. Tho mothod according to any procoding claim whoroin tho baking mixturo comprisos up to 65 wt% of a bulk sweetener.
6. The method according to any preceding claim wherein the baking mixture comprises at loast 5 wt% of an aquoous liquid.
7. An odiblo product formod from a baking mixturo comprising a sourco of starch and a liquid chocolato.
8. An edible product comprising a source of starch and a chocolate; wherein the chocolate is ovonly distributod throughout a solf-supporting, proforably crisp, matrix of cookod starch.
9. An odiblo product comprising a sourco of starch, a swootonor, a cocoa-dorivod product and a fat; whoroin tho cocoa-dorivod product and tho fat aro ovonly distributod throughout a solf-supporting, proforably crisp, matrix of cookod starch.
10. Tho odiblo product according to claim 12 whoroin tho odiblo product comprisos a sourco of starch, a sweetener, low-fat cocoa solids and a fat; and wherein the low-fat cocoa solids and the fat are evenly distributed throughout a self-supporting, preferably crisp, matrix of cookod starch.
II. Tho odiblo product according to claim 12 whoroin tho cocoa-dorivod product and tho fat both compriso cocoa buttor, and whoroin tho cocoa buttor is ovonly distributod throughout a solf-supporting, proforably crisp, matrix of cookod starch.
12. A method of manufacturing an edible product comprising chocolate, the method comprising the steps of: (a) providing a batter mixture comprising flour and a liquid; (b) mixing a liquid chocolate with the batter mixture to provide a chocolate batter mixture; (c) baking the chocolate batter mixture in a baking apparatus; wherein the liquid chocolate provides from 5 to 50 wt% of the chocolate batter mixture.
13. The method according to claim 12 wherein the edible product is a chocolate wafer product.
14. The method according to claims 12 or 13 wherein step (c) comprises baking the chocolate batter mixture between two baking plates.lb The method according to claim 14 wherein the baking plates are at temperatures in the range 140t to 220°C during baking.16. An edible product formed from a batter mixture comprising a flour, a liquid and a liquid chocolate.17. An edible product comprising a flour and a chocolate; wherein the chocolate is evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.18. An edible product comprising a flour, a sweetener, a cocoa-derived product and a tat; wherein the cocoa-derived product and the fat are evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.19. An edible product according to any of claims 16, 17 and 1 B wherein the edible product is a chocolate wafer product.20. A method of manufacturing an edible product comprising chocolate, the method comprising the steps of: (i) providing a batter mixture comprising flour and a liquid; (H) mixing a liquid chocolate with the batter mixture to provide a chocolate batter mixture; (Hi) baking the chocolate batter mixture in a baking apparatus; wherein the liquid chocolate provides from 5 to 70 wt% of the chocolate batter mixture.21. The method according the claim 20 whorein tho edible product is a chocolate wafer-roll product.22. A chocolate wafer-roll product formed from a batter mixture comprising flour, a liquid and a liquid chocolate.23. A chocolate wafer-roll product comprising flour and a chocolate; wherein the chocolate is evenly distributed throughout a self-supporting, preferably crisp, cooked flour matrix.24. A chocolate water-roll product comprising a flour, a sweetener, a cocoa-derived product and a fat; wherein the cocoa-derived product and the fat are evenly distributed throughout a self-supporting, preferably crisp, cooked flour matrix.25. A method of manufacturing an edible product comprising chocolate, the method comprising the steps of: (1) providing a baking mass comprising a source of starch; (2) mixing a liquid chocolate with the baking mass to provide a chocolate baking mass; (3) extruding the chocolate baking mass; wherein the liquid chocolate provides up to 20 wt% of the chocolate baking mass.26. An edible product formed from a baking mass comprising a source of starch and a liquid chocolate.27. An edible product comprising a source of starch and a chocolate; wherein the chocolate is evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.28. An edible product comprising a source of starch, a sweetener, a cocoa-derived product and a fat; wherein the cocoa-derived product and the fat are evenly distributed throughout a self-supporting, preferably crisp, matrix of cooked starch.