MXPA00012564A - Method of making heat-resistant chocolate and chocolate-like compositions with reduced apparent viscosity and products made thereby - Google Patents

Abstract

A heat-resistant chocolate or chocolate-like composition is prepared by mixing a polyol, such as sorbitol or glycerine, with a flowable chocolate or chocolate-like composition through an increased apparent viscosity phase. Upon continued mixing, the mixture returns to a reduced apparent viscosity (fluid) phase. The mixture is subsequently handled in the same manner as an unmodified composition. Upon aging and stabilization, the modified chocolate or chocolate-like composition demonstrates a reduced tendency to deform at elevated temperatures, is less prone to stick to packaging or fingers, and maintains the desired flavor, texture, mouth feel, and other characteristics of ordinary chocolate. The heat-resistant chocolate or chocolate-like composition of the invention is suitable for use in the same manner and for the same purposes for which ordinary chocolate and chocolate-like compositions are used, with the additional benefit of heat-resistance.

Description

METHOD FOR ELABORATING HEAT RESISTANT CHOCOLATE AND SIMILAR COMPOSITIONS TO CHOCOLATE WITH VISCOSITY REDUCED APPARENT AND PRODUCTS MADE BY THIS CROSS REFERENCE TO RELATED APPLICATION This application is the benefit of United States Provisional Patent Application Serial No. 60 / 089,437, filed on June 16, 1998.

PREVIOUS TECHNIQUE The present invention is directed to a method for forming a heat-resistant chocolate or chocolate-like composition and more particularly, to modified products that demonstrate reduced apparent viscosity in the melted phase. As a result of this reduced apparent viscosity, these products can be handled in the same manner as unmodified compositions. Such products have a reduced tendency to melt or deform at elevated temperatures and have a tendency to stick to fingers or wrapping materials. Chocolote products are typically samples of liquid cocoa, cocoa butter, sugar, lecithin and possibly milk and flavoring substances. The chocolate-like products contain substantially the same ingredients as a chocolate composition and also use any number of vegetable fats, extenders and / or cocoa butter replacers. Since the fat content resulting from these products is relatively high, the corresponding melting point is a function of the melting point of the fat contained therein. Products similar to chocolate or ordinary chocolate typically tend to melt at temperatures as low as 30 ° C. As a result, chocolate, chocolate, and chocolate-like candies for biscuits, cookies, and jams quickly lose their original appearance, and are no longer suitable for consumption when exposed to elevated temperatures. Many processes have been proposed to avoid some of the disadvantages normally associated with ordinary chocolate products. The products obtained by these various methods, which may have more heat resistance than their ordinary counterparts, often have a texture ("mouthfeel") or unpleasant taste, are costly to produce commercially, require separate production of ingredients, do not can occur within established manufacturing processes or are beyond the current legal definition for chocolate. US Patent No. 2, 166,806 discloses a product and method for preventing the separation of oils, specifically peanut products, such that such peanut products, for example, peanut butter, will have a reduced tendency to segregate. This patent describes the addition of glycerin, a polyol, to the peanut product, in an amount in excess of one tenth of one percent, and as high as twenty percent. However, the products and processes described in this patent apply only to peanut products. Potential uses with composition similar to chocolate and chocolate are not directed, it should be noted that peanut fat is substantially liquid at ordinary temperature (20 ° C) and therefore, has no relation to or any reference to melting. A disadvantage of this process is that the peanut product to be modified thickens quickly and allows little time for additional use of the product. Also, additional equipment is needed to incorporate glycerin in the last possible time before further processing to prevent premature establishment. In addition, the viscosity elevation and product value of the modified peanut product and its impact on the commercial production of the product are not addressed. European Patent No. 459,777 discloses a structured fat emulsion for incorporation into a confectionery coating as the fat ingredient. A disadvantage included with this process for producing a confectionary coating containing an emulsion of fat structure is that the described emulsions are inherently stable and therefore are difficult and expensive to produce and store. further, the machinery required to produce the emulsion is foreign to make chocolate, in this way significant additional capital investment may be required. Another disadvantage is that the preferred fat is partially hydrogenated fat. Such fats are thought to engender physiological properties that are currently thought to be undesirable, and are, therefore, commercially less desirable. Additionally, the use of such fats is not allowed since they are beyond the current legal definition for chocolate. The Patents of E. U. Nos. 5, 149,560; 4,446, 166; 4.081, 559; 4,045,583; and 2,904,438 and Swiss Patent No. 410,607 and 409,603 demonstrate the use of water or moisture in chocolate compositions. The products produced by the methods described in these patents are prone to suffer an effect known as "sugar fluorescence" and initiate a common oral sensation progressively increased as the water evaporates and the sugar crystallizes. Other disadvantages may include: lack of heat resistance below the immediate surface of the chocolate, the need for expensive heat treatments, controlled humidity and costly and difficult storage conditions, and poor quality of the finished products. Swiss Patents Nos. 399,891 and 489,21 1 describe methods for incorporating amorphous sugars into a chocolate composition during its manufacture. The sugars form a grid structure that prevent the collapse of the dough when the temperature exceeds the melting point of the chocolate fat. Such a structure is delicate, unstable and difficult to incorporate into a commercial establishment. U.S. Patent No. 4,446,166 describes a chocolate composition containing a water-in-fat emulsion that provides a product containing at least 20% of the fat in solid form. The water-in-fat mixture, however, does not remain in liquid form during processing. Also, the presence of such solid materials can result in a rough mouth feel or texture. Other methods of inclusion of humead or immobilization of fat have been proposed. A disadvantage described in the subsequent literature has been the increase in chocolate viscosity and product value that occurs as a result of the use of these methods. It is known that Newtonian liquids (for example, water) flow as soon as force is applied. The viscosity remains constant regardless of the cutting speed. Viscosity refers to the measurement of the internal friction of a fluid that provides resistance to cutting (movement) when a fluid is agitated or poured. The greater the internal frictional force (ie, higher viscosity), the less flow will be easier. Non-Newtonian liquids are liquids whose viscosities will vary according to the speed at which they are agitated (also known as "cutting speed"). "). They include plastic, dilatant and pseudoplastic liquids, characterized by the way in which a fluid viscosity changes in response to variations in cutting speed. 1 . Plastic. This type of fluid will behave like a solid under static conditions. Before the induction of any flow, a minimum force is required to initiate the movement of the liquid. 2. Dilatante. The viscosity increases with an increasing cutting speed. 3. Pseudoplastic. The viscosity reduces with an increasing cutting speed. The product value is the minimum force required to initiate the movement of a non-Newtonian liquid. When the product value in a non-Newtonian liquid is achieved and exceeded, fluidity results. The higher the product value, the more resistant the material to flow. "Plastic Viscosity" is a measurement that refers to the amount of energy required to maintain certain non-Newtonian liquids that move once they have begun to move. Melted chocolate is a non-Newtonian fluid, but is typically referred to as a pseudoplastic fluid, demonstrating unique theological characteristics. Chocolate viscosity measurements in the melted state can be referred to as "apparent viscosity", since variations in the cutting speed will affect the measured viscosity. Typically, apparent viscosity is a function of applied shear rate and shear stress regardless of the product value. See, Nelson and Beckett, Industrial Chocolate Manufacture and Use; 1988; Instruments and Control Systems. Vol.32 No. 6, June 1 959; and "More Solutions to Sticky Problems"; Brookfiled Engineering Laboratories, Inc., 1 985.

U.S. Patent No. 4,464,927 describes a method for increasing the viscosity of a chocolate composition so that the composition will not be flowable at good temperatures above the normal melting point of cocoa butter (or in the case of imitation chocolates, the melting point of vegetable fats and the like). This patent discloses adding a liquid polyol, for example, glycerin, sorbitol or mannitol from 0.2 to 5.0% by weight to a chocolate composition before tempering. A perceived disadvantage of this process is that the chocolate product to be modified is established rapidly, i.e. between 1 to 60 seconds, and allows little time for further processing of the chocolate, for example, molding and covering. Another disadvantage of this method is that special additional equipment may be needed to incorporate the polyol in the last possible time before further processing of the chocolate to prevent premature establishment of the chocolate. The U.S. Patent No. 5,523, 1 10 discloses a heat resistant chocolate comprising mixing a polyol gel in particulate form with a flowable chocolate or a flowable mixture of ingredients for preparing chocolate and chocolate-like compositions. The polyol gel is formed by the use of gelling agents such as pectin, xanthan gum, locust bean gum, kappa-carragahen agar, sodium alginate, gelatin, and iota-carragahen. Other gelling agents, such as polysaccharides, for example, glucomann, are suggested to be used to form a firm gel around a polyol. A disadvantage of this method is that such a gelling agent is not allowed in place by regulation in many countries, and therefore such compositions may not be labeled as "chocolate". Patent No. 5,523,110 also provides a gelation method by which a dry polyol mixture containing up to 95% by weight of water is used. A disadvantage of this method and process is that the product produced can have an undesirable taste and / or texture ("mouthfeel") due to the presence of a high amount of water in the chocolate. In addition, the patent further provides a method for forming and dispersing a particulate polyol gel by "cooling the polyol gel from about -170C to -200C and then grinding it in a cold grinder." A disadvantage of this method and process is the prohibitive use of cost of refrigerants such as liquid nitrogen needed to achieve low temperatures. Such a technique is foreign to commercial chocolate production. The U.S. Patent No. 5,445,843 discloses a process for improving the heat resistance of chocolate or chocolate-like products with a reduced tendency to deform at elevated temperatures which includes the step of mixing an encapsulated polyol within an edible lipid, eg, fat or oil, and added in a particulate form to a flowable chocolate composition. The resulting chocolate product is described as having a slower "settling time" when compared to other methods. A disadvantage of this process is that in a commercial establishment, it may be difficult to maintain the required "soft mixing" of the composition. That is, pumps, mixers and other operations in a commercial chocolate production establishment may apply more mechanical energy than that allowed by this patent. In addition, commercial chocolate is best stored at about 40 ° C. See, R. B. Nelson and S. Beckett, Industrial Chocolate Manufacture and Use (1 988). In addition, commercial chocolate typically melts at 60 ° C, decreases to between 46 and 49 ° C; and pumps at a temperature between 43.5 and 49 ° C before tempering. See, D. Hawk, er al. National Confectioner's Association -All Candy Expo educational session "Chocolate Handling, Problems and Solutions", (June 12, 1997). The handling of chocolate modified beyond the parameters established by Patent No. 5, 445,843 can cause premature establishment of modified chocolate and, in a commercial setting, can result in disastrous consequences. Other disadvantages of this process are that the encapsulated particulate must be produced as a separate ingredient, and the particulate must be stored to remain in solid form during the mixing and processing of the chocolate composition to prevent premature establishment. The U.S. Patent No. 5,445,843 provides the following example: "5 parts of the encapsulated glycerol as prepared ... is mixed with 1 00 parts of a flowable chocolate mixture in shell at 30 degrees C for 15 minutes.The chocolate remains flowable for several minutes without establishment ... " It is well known to those skilled in the art that melted chocolate in a commercial establishment must remain flowable for many hours. It has been described and demonstrated in the prior art discussed above that the increase in viscosity of a chocolate composition by inclusion of water or polyol would render certain methods impractical or unusable in a commercial establishment. The prior art teaches that imitation chocolate and chocolate compositions which exhibit high viscosity in their fluid phases are to be avoided. It is also self-evident to those skilled in the art that a method for producing heat-resistant chocolate compositions considered typical for the manufacture of chocolate could be preferred over the use of special processing equipment. In addition, the special handling of ingredients and / or finished products, for example, high humidity or storage at low temperature is not a preferred approach.

DESCRIPTION OF THE INVENTION The present invention is designed to overcome the deficiencies of the prior art discussed above. It is an object of the present invention to provide a composition similar to chocolate or modified chocolate with reduced apparent viscosity in the melted state, which has the taste, texture and mouth feel of traditional chocolate or chocolate-like compositions. It is a further object of this invention to provide a method for making a chocolate-like or heat-resistant chocolate-like composition that is little or less complicated than the traditional method of making chocolate. The present invention includes a method for adding a polyol to a composition similar to chocolate or chocolate. The viscosity rise normally associated with the introduction of the polyol is overcome by the continuous mixing of the composition through a stage of high apparent viscosity until the composition returns to a reduced apparent viscosity and flowable state. These and other objects, features and advantages of the present invention will be clearly understood through a consideration of the following detailed description.

BEST MODE FOR CARRYING OUT THE INVENTION According to the present invention, 0.5 to 20% by weight of a liquid polyol, for example, glycerin, is added to a mixture similar to chocolate or flowable chocolate before or after the mixture is quenched. The liquid polyol is mixed with the chocolate or chocolate-like composition at normal processing temperatures, for example about 37.77 ° C. The composition is mixed through a phase of increased product value and apparent viscosity, showing reduced flow characteristics, eg, a "plastic phase" for a time, until the composition has returned to a flowable composition. The viscosity of the modified composition shows increased product value. However, the apparent viscosity is substantially the same as or less than the unmodified composition. The modified composition is handled in substantially the same manner as an unmodified composition, and can remain flowable for several hours to several days. After a modified composition is produced and preserved for a time, the composition will demonstrate improved heat resistance. (The term "reduced apparent viscosity" refers to the viscosity of the composition which, when modified, is still in its melted state as compared to an unmodified composition.). After returning to the flowable state, the chocolate-like or modified chocolate-like composition can be tempered, deposited, molded or used as a coating, and when allowed to mature and stabilize, develops heat resistance. The modified set composition has an extended "run time" of sufficient duration for subsequent handling in the same manner as traditional chocolate. In addition, the modified chocolate composition can be produced without the expensive methods and ingredients described in the prior art. In carrying out the process of the present invention, the chocolate composition that is to be modified may be a milk chocolate, a semi-sweet chocolate, a white chocolate, or any composition known as a "composite", "jam" or "cake". The coating may contain any edible fat or oil. Ordinarily, the fats used are animals or vegetables in origin and are edible. However, synthetic materials that have chemical compositions substantially similar to fats and oils can also be used. Preferred oils and fats are low melting greases that show some tendency to flow at slightly elevated temperatures or environment. These include cocoa butter, other shortening products, peanut oil, and vegetable oils. Nevertheless, substantially any fat or oil can be converted into a product and rendered useable, i.e., mixed through a flowable state by use of the method of the present invention. In a preferred embodiment, the invention is particularly applicable to products containing low melting point oils or fats, for example, imitation chocolate or chocolate products. The polyols that can be used are branched or straight chain hydrocarbon compounds containing at least two hydroxyl groups in the carbon structure. Compounds that include other functional groups, for example, double bonds or carboxyl groups, can also be used, provided that at least two hydroxyl groups are present. There is no upper limit to the number of carbon atoms or hydroxyl groups that may be present in the structure. Polyols are generally not soluble in fats or oils and as a result, those that occur naturally as liquids are preferred. Glycerin, for example, is preferred as a matter of convenience, although other polyol materials which readily form solutions having a substantial concentration of the polyol, for example sorbitol, are acceptable. Other materials that can be used in the invention include mannitol and corn syrup, for example, 42 D.E., 55 D. E. The continuous mixing can be done during the chocolate making or after chocolate making. If the mixing occurs after the preparation of chocolate, it may be before tempering, after tempering or during tempering of the chocolate. The continuous mixing can be low cut, such as in a planetary mixer, or high cut, such as in a scratched surface heat exchanger. Continuous mixing can be done at low speed or high speed. In the production of compositions similar to chocolate and modified chocolate, any formulation similar to conventional chocolate or chocolate can be employed. Such formulations typically include chocolate liquor, milk solids, sugar, cocoa butter, cocoa butter replacers, lecithin, and flavorings. Other ingredients, all of which are known to those skilled in the art, can also be used. Typically, the ingredients used to make a composition similar to chocolate or chocolate are mixed, refined, conched, and standardized in terms of viscosity, tempered and used to form a finished product or to dress or coat a preformed center. The finished product is then cooled or cooled typically after it is put into its final form. The invention will be further understood through the following non-restrictive, illustrative examples. Example 1 A 600 gram sample of a commercially available milk chocolate (Cashemere Brand Milk Chocolate, Wilbur Chocolate, Litiz, PA) was placed in a five quart quart Hobart mixer, and melted at about 47 ° C. Five percent glycerin was added and mixing continued. Within about 45 seconds, the sample becomes highly viscous. The mixture continued, and within 20 minutes, the sample became again flowable. The sample is then tempered and molded in the traditional way. Within 24 hours, the sample becomes resistant to heat. Example 2 A 600 gram sample of the same flowable chocolate of Example 1 was placed in a five quart quart Hobart mixer where it was melted at about 47 ° C. Five percent glycerin was added and the sample was returned to mixed. Once the sample has returned to a fluid state, the mixer is then set at a low mixing speed and left about thirty (30) hours. The sample is then tempered, molded and cooled in the traditional way. The sample becomes heat resistant after three days. Example 3 A 20 kilogram sample of a commercially available milk chocolate (Sable Brand Milk Chocolate, Wilbur Chocolate, Litiz, PA) was placed in an 80-quart Hobart mixer and melted at approximately 47 ° C. The chocolate was then cooled to approximately 38 ° C. Three percent glycerin was added and the sample was mixed. After 15 minutes the sample becomes fluid. The sample was tempered, molded and cooled in the traditional way. The sample becomes resistant to heat after two days. Example 4 A 230 kilogram sample of the same chocolate used in Example 3 was placed in a swept surface blender mixer and melted at about 47 ° C. The chocolate was then cooled to approximately 38 ° C. Three percent glycerin was added. The sample was then mixed. Within 30 minutes the sample becomes fluid and is pumped, tempered, molded and cooled in the traditional way. The sample becomes heat resistant after three days. Example 5 A semi-sweet chocolate was prepared for the following formula: Ingredients Parts in Weight Refined sugar 50 Chocolate liquor 40 Cocoa butter 9.7 Lecithin 0.3 Total 1 00 The above material is mixed in a Hobart 12 quart mixer for 6 hours at 50 ° C. The sample is cooled to 40 ° C. Eight parts of a polyol are added to the composition, and the sample is mixed until the sample becomes again flowable. The sample is then tempered, molded and cooled in the traditional way. The sample becomes resistant to heat during the night. Example 6 A 600 gram sample of a "chocolate paste candy" or confectionery coating (Bloomer Chocolate Company, Chicago, IL) was placed in a five quart quart Hobart mixer and melted at about 47 ° C. Eight percent of a polyol was added and the mixing continued. Within 45 minutes the sample became flowable. The sample is then used to cover the whole wheat crackers. Within 48 hours, whole wheat crackers become heat resistant. It will be readily apparent to those skilled in the art that a wide variety of food, pharmaceutical and other compositions can be formulated using the method of the invention to produce a wide variety of new products. The present invention can be included in other specific forms without departing from the spirit or essential attributes thereof and according to the above, reference should be made to the appended claims rather than to the specification, since they indicate the scope of the invention

Claims (8)

1. CLAIMS 1. A method for producing a composition similar to heat resistant chocolate with reduced apparent viscosity comprising the steps of: providing a composition similar to flowable chocolate; adding a polyol to said composition to form a mixture having an increased apparent viscosity; and continuously mixing said mixture until said mixture has a reduced apparent viscosity.
2. 2. The method for producing a composition similar to heat resistant chocolate with reduced apparent viscosity according to claim 1, characterized in that said polyol is a liquid.
3. 3. The method for producing a composition similar to heat resistant chocolate with reduced apparent viscosity according to claim 1, characterized in that said polyol is glycerin.
4. 4. The method for producing a heat-resistant chocolate-like composition with reduced apparent viscosity according to claim 1, further including the step of quenching said composition prior to said addition step.
5. 5. The method for producing a heat-resistant chocolate-like composition with reduced apparent viscosity according to claim 1, further including the step of quenching said mixture after said addition step.
6. 6. The method for producing a heat-resistant chocolate-like composition with reduced apparent viscosity according to claim 1, further including the step of quenching said composition during said addition step.
7. 7. The method for producing a composition similar to heat resistant chocolate with reduced apparent viscosity according to claim 1, characterized in that said chocolate-like composition is chocolate.
8. 8. In a composition similar to chocolate or heat resistant chocolate, the improvement comprising said composition showing a high product value and a reduced apparent viscosity in the melted state.