OA18584A - Cocoa products based on unfermented cocoa beans and methods for preparing the same. - Google Patents

Abstract

Disclosed is a method for processing unfermented cocoa beans, comprising the steps of: (a) adding water to said unfermented cocoa beans to form a suspension; (b) wet grinding said suspension; (c) subjecting said suspension to a heat treatment at a temperature of 70°C or less; (d) separating the suspension into a water phase (heavy phase), a fat phase (light phase) and a solid phase, said fat phase comprising cocoa butter as a major component and solids and/or water as minor components and said solid phase comprising cocoa powder and water; and (e) separately processing the three phases, which optionally comprises: separating cocoa butter from the fat phase, separating cocoa powder from the solid phase, and separating cocoa aroma and a polyphenolic powder from at least the water phase. Further disclosed are methods of manufacturing of a cocoa product construction kit and chocolate or chocolate-like products comprising high amounts of nutritionally beneficial and useful components of the cocoa fruit, such as e.g. polyphenols, antioxidants, vitamins and/or sugars, making use of the above technique.

Description

COCOA PRODUCTS BASED ON UNFERMENTED COCOA BEANS AND METHODS FOR PREPARING THE SAME

FIELD OF INVENTION [0001] This invention relates to methods and/or techniques for the production of chocolaté or chocolate-like products on the basis of unfermented cocoa beans, wherein the products exhibit reduced bittemess and astringency and at the same time comprise high amounts of nutritionally bénéficiai and useful components of the cocoa fruit, such as e.g. polyphenols, antioxidants, vitamlns and/or sugars.

[0002] In certain embodiments, this invention relates to the processing of unfermented cocoa beans and optionally cocoa pulp/mucilage for the manufacturing of a cocoa product construction kit as well as chocolaté or chocolate-like products comprising high amounts of nutritionally bénéficiai and useful components of the cocoa fruit, such as e.g. polyphenols, antioxidants, vitamlns and/or sugars.

BACKGROUND OF THE INVENTION [0003] Cocoa (Theobroma cacao L) Is known as an Important source of healthy ingrédients, such as e. g. minerais, vitamlns, polyphenols (especlaily catechins, anthocyanidins and proanthocyanidins), and antioxidants such as flavonoids, which are inter alia physioîogicaîly active in the réduction of oxldative stress, Inhibition of low-density lipoprotelns (LDL) oxidation and platelet aggregation, and are acting as vasodilators In blood vessels.

[0004] However, during conventional processing of cocoa beans in the manufacture of cocoa-based foodstuffs, which Involves fermentation and drying/roasting at high températures, substantial amounts of polyphenols, antioxidants, and/or vitamins are lost when compared to their contents in raw cocoa beans. A few variants of such conventional methods are disclosed In US 2006/257547 A1 and GB 622 628 A.

[0005] A typical cocoa bean processing procedure beglns with the harvest of the cocoa pods, followed by careful removal of the cocoa beans. Thereafter, the cocoa beans are fermented and dried. As with most organic material, fermentation of cocoa begins almost immediately upon exposure to air. Spores from naturally occurring yeasts settie on the sugary beans and start to split the sugar into carbon dioxide, aroma and alcohol, the latter being further converted into acetic acid by means of microbial activities provided by bacteria. At the final stage of this process (in the following referred to as “natural fermentation process”), germ within the cacao bean is inactivated by the presence of alcohol, acetic acid and the heat generated by said microbial activities, resulting in a release of enzymes capable of reducing astringency within the bean, which are believed to be important to the development of the chocolaté flavor. Typically, this natural cocoa fermentation process being spontaneously induced by microbial activities takes place during about two or more days until the microbial activities are inhibited by an excess of acetic acid and/or heat being caused by said microbial activities. Since much of the acetic acid is left within the beans after the fermentation is complété, it has to be removed from the beans in order to avoid sour and biffer flavors in the final cocoa product caused by the presence of acetic acid. Conventionally, the concentration of acetic acid is reduced during a roasting step at typically 70 to 180^eC, which inevitably leads to a réduction of désirable healthy cocoa ingrédients.

[0006] As an alternative to the Inhibition of germination of cocoa beans by natural or spontaneous cocoa fermentation, the Inhibition can also be brought about by certain physical and/or chemical pre-treatments applied to freshly harvested cocoa beans shortly after removal of the beans from the pods. Thereby, microbial fermentation may be avoided in order to reduce the variation in flavor and taste profile in the final cocoa products due to lack of control over the natural fermentation process. Such a pre-treatment typically Involves incubation of freshly harvested cocoa beans at an elevated température, e.g. at a température of between 25 and 70 °C for less than 24 hours, as is disclosed in US patent US 8,501,256 B2. WO 2014/130539 A1 discloses an Incubation process, wherein unfermented cocoa beans are incubated in ethanolic solution at a température of less than 55^eC for 24 to 96 h.

[0007] However, the taste characteristics of unfermented and unroasted bean products are typically described as bitter, unpalatable, and being accompanied with a high level of astringency mainly due to the presence of catechins (which include epicatechin, catechln, procyanldin B2, procyanidln B5 and procyanidin C1) and amino acids (T. Stark et al., J. Agric. Food Chem. 2005, 53, 5407-5418), so that in order to produce a cocoa product with an acceptable flavor, cocoa product manufacturera have to either subject unfermented and/or Incubated beans to an extensive heat treatment (such as In a drying and/or roasting step, which Is usually carried out at about 100 to 150°C) to reduce the content of the bitter and astringent components (which is inevitably accompanied by the loss nutritionally bénéficiai and useful components of the cocoa fruit), or blend unfermented and/or Incubated beans with fermented beans to achieve a compromise between taste quality and healthinducing effects.

[0008] WO 2010/073117 discloses a method for processing cocoa beans comprising the formation of a suspension comprising cocoa beans or nibs and water, wet grinding the suspended beans or nibs, heating the suspension, and decanting the same such that said suspension is separated into a water phase, a fat phase and a solid phase, In order to avoid liquéfaction of the cocoa fat and formation of a chocolaté liqueur during mechanical processing.

[0009] However, the problem of providing a method for processing cocoa beans which allows to manufacture cocoa products that are characterized by a pleasant taste and at the same time comprise favorably high amounts of nutritionally bénéficiai and valuable components of the unfermented cocoa fruit, such as e.g. poiyphenols, antioxidants, vitamins and/or sugars, has hitherto not been adequateiy addressed.

[0010] The présent invention has been made In view of the above enumerated drawbacks and/or desires for improvements in the art.

SUMMARY OFTHE INVENTION [0011] The présent invention solves this object with the subject matter of the daims as defined herein. The advantages of the présent invention will be further expiained In detail in the section below and further advantages wili become apparent to the skiiled artisan upon considération of the invention disclosure.

[0012] Generally speaking, in one aspect the présent Invention provides a method for processing unfermented cocoa beans, comprising the steps of: adding water to said unfermented cocoa beans to form a suspension; wet grinding said suspension; subjecting said suspension to a heat treatment at a température of 70°C or less; separating the suspension into a water phase (heavy phase), a fat phase (light phase) and a solid phase, said fat phase comprising cocoa butter as a major component and solids and/or water as mlnor components and said solid phase comprising cocoa powder and water; and separately processing the three phases, which optionally comprises: separating cocoa butter from the fat phase, separating cocoa powder from the solid phase, and separating cocoa aroma and a polyphenolic powder from at least the water phase.

[0013] A further aspect of the présent invention is the provision of a construction kit for chocolaté or chocolate-iike products, comprising the cocoa butter, cocoa powder, polyphenolic powder and cocoa aroma extracts obtained by the processing method as described above.

[0014] In another aspect, the présent invention provides a method for producing chocolaté or chocolate-iike products comprising the steps of: adding water to unfermented cocoa beans to form a suspension; wet grinding said suspension; subjecting said suspension to a heat treatment at a température of 70°C or less; separating the suspension Into three phases, I.e. a water phase (heavy phase), a fat phase (light phase) and a solid phase, said fat phase comprising cocoa butter as a major component and solids and/or water as mlnor 5 components and said solid phase comprising cocoa powder and water; and separately processing the three phases, which comprises: separating cocoa butter from the fat phase, separating cocoa powder from the solid phase, and separating cocoa aroma and a polyphenolic powder from at least the water phase; recombining the cocoa aroma extract with the cocoa butter extract; mixing the recomblned extracts with said cocoa powder extract, 10 said polyphenolic powder extract and/or milk powder; and conching said mixture.

[0015] A further aspect of the présent Invention is a chocolaté or a chocolate-like product obtained by using the aforementloned methods or the aforementloned construction kit.

BRIEF DESCRIPTION OFTHE DRAWINGS [0016] FIG. 1 schematically illustrâtes the method for processing the fermented cocoa beans up to the provision of a cocoa product construction kit, as well as the foilowing method of manufacturing chocolaté according to the subject invention.

[0017] FIG. 2 schematically illustrâtes an exemplary treatment of the water phase upon 20 phase séparation.

[0018] FIG. 3 schematically Illustrâtes the method of manufacturing chocolaté or chocolatelike products.

[0019] FIG. 4A schematically illustrâtes an exemplary method for preparing dark chocolate/milk chocolaté using the fractions obtained after séparation and processing of the 25 fat, solid and water phases.

[0020] FIG. 4B schematically illustrâtes an exemplary method for preparing white chocolaté using the fractions obtained after séparation and processing of the fat, solid and water phases.

[0021] FIG. 40 schematically Illustrâtes an exemplary method for preparing a chocolaté or 30 chocolate-like product with 100% cocoa using the fractions obtained after séparation and processing of the fat, solid and water phases and cocoa pulp/mucilage as a natural sweetener.

DETAILED DESCRIPTION OFTHE INVENTION [0022] For a mors complets understanding of ths présent Invention, reference Is now made to the following description of the illustrative embodiments thereof:

Method for Processlng Unfermented Cocoa Beans [0023] The method for processing unfermented cocoa beans according to a first embodiment of the présent invention is generaily characterized by the steps of: (a) adding water to said unfermented cocoa beans to form a suspension; (b) wet grinding said suspension; subjecting said suspension to a heat treatment at a température of 70^eC or less; (c) separating the suspension into a water phase (heavy phase), a fat phase (light phase) and a solid phase, said fat phase comprising cocoa butter as a major component and solids and/or water as mlnor components and said solid phase comprising cocoa powder and water; and (d) separately processing the three phases, which optionally comprises: separating cocoa butter from the fat phase, separating cocoa powder from the solid phase, and separating cocoa aroma and a polyphenolic powder from at least the water phase.

[0024] The expressions separating cocoa butter from the fat phase and separating cocoa powder from the solid phase refers to operations by which a concentration of the major components cocoa butter (in the fat phase) or the cocoa powder (in the soiid phase) , respectively, Is achleved. The expression “separating cocoa aroma and a polyphenolic powder from at least the water phase” refers to operations by which cocoa aroma and polyphenolic powder are retrleved from the respective phase in a concentrated form. These operations may Include, but are not limited to filtration, drying processes (e.g. évaporation of residual water, optionally under vacuum conditions) and/or centrifugation, for example.

[0025] The expression fermentation generaily refers to any activity or process involving enzymatic or metabolic décomposition (digestion) of organic materials by microorganisms, and encompasses both anaérobie and aérobic processes, as well as processes Involving a combination or succession of one or more anaérobie and/or aérobic stages. The terme “unfermented”, as used herein, refers to the fermentation degree of the cocoa beans. As Is known by those skilled In the art, the degree of fermentation is denoted by the fermentation index (cf. Shamsuddin and Dimick, Qualitative and Quantitative Measurements of Cacao Bean Fermentation, in Proceedings of the Cacao Biotechnology Symposium, Ed. P. S. Dimick, p. 55-74, The Pennsylvania State University, 1986). In general, the fermentation Index of unfermented beans is less than 0.5.

[0026] The unfermented cocoa beans may hâve undergone a number of processing steps prior to being used for the initial step (a) of adding water, a few of which will be explained In the following:

[0027] In the fruit pod of Theobroma cacao, typically about 30 to 50 fruit seeds (i.e. cocoa beans) are surrounded by pulp and mucilage Inside the pods. After the pods are harvested and opened mechanlcally or manually, which is preferably carried out In a sanltary facility, the cocoa beans are separated from the shell of the cocoa fruit.

[0028] Depending on the desired taste characterlstics, the unfermented cocoa beans may be used In method step (a) in a depulped form or together with a part of or the entire pulp and mucilage contained in the pod.

[0029] The depulplng of the cocoa beans may be carried out manually or mechanlcally. In a preferred embodiment, the pulp and mucilage is separated from the beans by using a mechanical séparation device. In a further preferred embodiment, the cacao beans are separated from the pulp and mucilage by a paddle separator having a cylindrical screen with a rotating central axle on which paddle blades are affixed, wherein the blades sweep around the cylindrical screen and pulp and mucilage is sleved through the cylindrical sieve without causing damage to the cocoa beans. An exemplary mechanical separator which may be used for this purpose is known from US 2013/0316056 A1. The advantage of such a mechanical séparation Is that in a short processing time a high séparation yield may be achieved, which allows a maximum amount of the pulp and mucilage to be relntroduced Into the intermediate products and/or extracts during the further steps of the methods of the présent Invention, which will be explained In further detail below.

[0030] In a preferred embodiment, the cocoa pulp and mucilage obtained in the depulplng step Is processed se parais ly from the unfermented cocoa beans and subsequently added to the suspension before or during steps (a), (b), (c) or (d). In an altematively preferred embodiment, the pulp may be re-introduced at a later stage as a natural sweetener, so that advantage Is taken of its relatively high sugar content. Advantageously, said approaches allow a maximum amount of the nutritionally bénéficiai components of the pulp and mucilage to be relntroduced into the Intermediate products, extracts and final cocoa product and allow a variable fine tuning of the flavors In the extracts and the final product. The pulp and mucilage to be relntroduced may be derived from the same cultiver as the cocoa beans, which may be advantageous e.g. if the extracts and/or the final cocoa product is Intended to be a pure-origin product. Altematively, the pulp may be derived from a different cultiver than the cocoa beans or be a blend of different cultivars.

[0031] In a preferred embodiment, the separate pre-processing of the cocoa pulp and mucilage obtained In the depulping step may comprise mechanical and/or chemical séparation and removal of undesired components. Such undeslred components may comprise residual shell components and compounds contributing to an overly bittor, acidic and/or unpalatable teste, for example. In a further preferred embodiment, the separate processing of the cocoa pulp and mucilage obtained in the depulping step comprises neutraltzing and/or removing acidic components, such as e.g. citric acid and/or acetic acid. Advantageously, said embodiment allows to produce extracts and cocoa products, wherein the taste characteristics are not excessively dominated by the acidic flavor of the pulp, and wherein at the same time high amounts of nutritionally bénéficiai components originating from pulp and mucilage are contained. In a further embodiment, alone or in combination with the above embodiments, the pre-processing of the pulp/mucilage may comprise a step of separating the sugars from or concentrating the sugars In the pulp, e.g. by extraction methods or the like. Said embodiment is especially préférable if cocoa pulp is intended to be used as a natural sweetener within the cocoa product.

[0032] In a preferred embodiment, the unfermented cocoa beans may be pre-treated in an incubation step with or without cocoa pulp and mucilage prior to step (a). Such an incubation step Is characterized in that it inhibits the germination of cocoa beans by certain physical and/or chemical pre-treatments shortly after removal of the beans (with or without pulp and mucilage) from the pods.

[0033] In particular, it is possible to Inhibit germination of cocoa beans by Incubating freshly harvested cocoa beans at an elevated température, e.g. at a température of between 10 and 70 °C, preferably at a température of between 10 and 55°C for a period of between 2 hours and 10 days, preferably between 3 and 168 hours, in an incubation medium. As will be known to the skilled artisan, it is particularly préférable to transfer the cocoa beans (optionally together with the pulp/mucilage) to the incubation medium immediately after opening the pod, preferably under stérile conditions, in order to suppress spontaneous fermentation as effectively as possible.

[0034] The incubation medium is not specifically limited and may be an aqueous acidic medium, as Is e.g. used In the cocoa bean processing method disclosed in US 8,501256 B2, or an aqueous éthanol solution, for example.

[0035] In conventional cocoa bean processing methods, using an aqueous acidic medium as incubation medium may be disadvantageous in that substantiel amounts of the acid used (usually inorganic or organic acids with preference for amphlphllic acids, while acetic acid is especially preferred since It has been shown to effectively penetrate the cocoa beans and pervade biological membranes) remain in the bean, which hâve to be subsequently removed by thermal treatment or alkalization, or otherwise resuit in a sour and/or bitter flavor in the final product. Furthermore, spontaneous microbial activities occurring under non-sterile conditions may further contribute to formation of acetic acid. The method of the présent invention has the advantage that such acid residues may be effectively dealt with by removing the acid via the water phase obtained in step (c) by neutralization, distillation, extraction, emulsion-type liquid membrane processes, salting out or combinations thereof, without the necessity to Increase the thermal load upon the cocoa solids or to treat the cocoa solids via alkalization, so that a favorably high amount nutritionally bénéficiai components may be preserved and a pleasant, non-bitteror non-acldic taste may be achieved.

[0036] In a preferred embodiment, the Incubation medium Is an aqueous éthanol solution, wherein the unfermented cocoa beans are Incubated at a température of between 10°C and 70^eC, preferably at a température of between 10 and 55^e for a period of between 2 hours and 10 days, preferably between 3 hours and 96 hours, wherein the volume of the aqueous éthanol solution Is sufficient to cover the cocoa beans. Such an incubation step is advantageous In that it représente a simpie, reproducible and controllable alternative to microblal (Le. yeast and bacterlal) fermentation, while at the same time a pleasant cocoa flavor and taste profile may be achieved. Although not being particularly limited as long as the concentration of éthanol Is sufficiently high to prevent spontaneous fermentation by endogenous microbes, the concentration of éthanol in the incubation medium may be from 1 to 90 vol.-%, preferably between 1 and 12 vol.-%. In an especially preferred embodiment from the vlewpoint of germination Inhibition efficiency and processing costs, the concentration of éthanol in the Incubation medium Is at least 2 vol.-% and less than 7 vol.-%.

[0037] The Incubation medium may further comprise enzymes known in the art for controlied enzyme-catalyzed reactions In order to facilitate formation of aroma precursors, such as hydrophilic oligopeptides and hydrophobie free amino acids, for example.

[0036] If applied, the incubation may be carried out in a single step or In multiple incubation steps, wherein different incubation conditions and/or incubation media are employed. As will be known to the skilled artisan, the Incubation conditions, such as pH or température, may be varied within one single incubation step.

[0039] The incubation step may further encompass one or more mechanical and/or physical treatment steps commonly known in the art before or during the incubation. Although not being limited thereto, such a mechanical treatment may comprise stirring, mixing and agitating, and combinations thereof, while said physical treatment may comprise an infra-red treatment and/or a vacuum treatment, for example.

[0040] In case the unfermented cocoa beans hâve been incubated In accordance to any of the above-defined steps, the cocoa beans may be removed from the Incubation medium and subjected to step (a) or subjected to step (a) with the Incubation medium.

[0041] In a preferred embodiment, the incubated unfermented beans are subjected to step (a) without an Intermediate drying step. In a further preferred embodiment, the unfermented cocoa beans used for step (a) hâve not been predried at ail. These embodiments are especially advantageous in terms of processing costs due to the lower energy expenditure.

[0042] As a starting material for step (a), whoie unfermented cocoa beans that may hâve been Incubated may be used, or unfermented cocoa beans which are subsequently subjected to a breaking step during which the beans are broken into smalier, non-whole bean particles (e.g., cocoa nibs).

[0043] The subject cocoa processing technique generally beglns in step (a) with forming a suspension of unfermented cocoa beans by adding water, either prior or during the grinding of the cocoa beans/nibs.

[0044] Water is added to form the cocoa bean suspension. While not being particularly limited, the weight ratio of water to cocoa beans/nibs In the formed suspension is preferably between 1:1 to 6:1, more preferably 2:1 to 4:1, especlally preferably about 3:1, whtch may advantageously affect the processability in the further steps (e.g. facilitated pumping, grinding and easier phase séparation).

[0045] If désirable from the viewpoint of introducing additional flavors, alternative watercontaining liquide may also be used as a source of water, preferably liquids selected from one or more of coffee, tea and liquids having water contents of from 60 to about 95 % by weight, such as fruit juices, fruit juice concentrâtes, or milk, for example. In a preferred embodiment, cocoa pulp and mucilage, which may hâve accompanied the unfermented cocoa beans and nibs during the previous steps; which may hâve been separated from the beans, processed In accordance to the abovementioned method and re-added to the beans prior to step (a); or which may hâve been obtained otherwise, is used as an additional source of water, either atone or In combination with any water-containing liquids mentioned above. In case such water-containing liquids are used, It is generally préférable that the water content in the formed suspension faits into the above-defined ratios. Since the thermal load In the further method steps Is relatively low, temperature-sensitive flavors origlnating from said liquids are retalned and may favorably interact with the primary and secondary flavors of the cocoa bean.

[0046] In order to obtain coffee-fiavored cocoa products, coffee beans (whoie or broken, unroasted or roasted) may be mixed to the unfermented cocoa beans/nibs when forming the suspension In water, provided that the cocoa beans/nibs form the major part In the bean mixture so that the content of coffee beans does not interfère or negatively affect the wet milling and phase séparation steps. Preferably, the coffee bean content Is less than 20% by weight of the bean mixture, more preferably less than 10% by weight.

[0047] In step (b), the unfermented cocoa beans/nibs are subjected to a single or multiple wet grinding step(s), which resuit in bean particle sizes of preferably 50 pm or smalier, more preferably 40 pm or smalier, even more preferably 20 pm or smalier. Reducing the bean particles to such a size range substantially Increases the exposed surface area of the bean particle material therefore allowing it to be more efficiently wet (e.g., with water rather than a chemical solvent) for Improved extraction results (such as improved extraction of fats or lipids, aromatic substances, and/or polyphenols). The bean particle slze réduction may be accomplished by using dise mills (e.g. perforated dise mill), colloid mills (e.g. toothed collold mills), or corundum stone mills, for example. It Is préférable that In at least one grindfng step, cocoa bean cells are macerated to enable the solvent (water) to wet the cocoa bean material better due to increased available surface area of the macerated cocoa beans. The methods and devices used for wet milling are not particularly limited as long as undesirable émulsification by significant frictlonal heat production or high mechanlcal forces is avoided. For example, when using multiple grinding steps, a coarse wet grlndlng step (e.g., optionally with further water) may be carried out using a perforated dise mill, and the coarsely milled suspension may be pumped to a toothed collold mill for a fine grinding step.

[0001] After the wet grinding step (b), the suspension is subjected in step (c) to a thermal treatment at a température of no more than approximately 70°C in order to reduce the overall thermal load and prevent émulsification, ln a preferred embodiment, previously separated cocoa pulp and mucilage (unprocessed or processed separately from the unfermented cocoa beans) Is added to the suspension before step (c), so that It may contribute to the development of secondary flavors during Maillard reactions occurring at elevated températures. From the vlewpolnt of a favorable balance of cocoa butter yield and préservation of désirable flavors, such as aromatics, anti-oxidants and/or vitamins, heating températures of from 43 to 65’C are préférable, ln terms of cocoa butter liquéfaction and/or Improved mechanical phase séparation, a heating température range of from 45 to 50°C is particularly préférable. Without being limited thereto, heating of the wet-milled suspension may be carried out by a scrap or tube heat exchanger.

[0048] Therealter, phase séparation is carried out in step (d) so that three phases, l.e. a water phase (heavy phase), a fat phase (light phase) and a solid phase are obtained, said fat phase comprising cocoa butter as a major component and solids and/or water as minor components and said solid phase comprising cocoa powder and water. Preferably, devices employing centrifugal forces may be utilized to achleve mechanical particie séparations, such as decanters or nozzle separators. For Instance, the suspension may be decanted to separate coarse or large or high mass solids from liquid(s) and then smaller and/or fine solid particles may be further separated from liquide and/or oll products may be separated from non-oil products.

[0049] Multiple phase séparation and recombination steps may be employed to achieve an improved séparation between the water phase (heavy phase), the fat phase (light phase) and the solid phase. For example, the fat phase obtained by an Initial decanting step may be further filtered or centrifuged to separate remaining fine particles or water from the fat phase and the thus obtained fine particles and water may be recombined with the water and soiid phases from the Initial decantlng step or at a iater processing stage of said phases. Also, the water phase may be subjected to further purification steps, e.g. by filtration using vacuum 5 rotation filters in order to remove fine particles and reduce cloudiness of the liquid.

[0050] Upon séparation of the three phases (i.e. the water phase (heavy phase), the fat phase (light phase) and the solid phase), these may be independently processed to separate cocoa butter (from the fat phase), cocoa powder (from the solid phase), cocoa aroma (from at least the water phase, optionally also from the solid phase) and a polyphenolic 10 concentrate (from the water phase), as is illustrated by Fig. 1.

[0051] As indicated above, the fat phase (light phase) may be filtered (e.g. by employing a vibrating screen) and/or conveyed to a 3-phase separator (e.g. centrifuge) to remove fine particles (which may be optionally added to the solid phase prior or during the drying/roasting step) and residue water (which may be optionally added to the water phase prior to aroma 15 recovery). Cocoa butter is obtained by filtering the purified fat phase.

[0052] The (wet) solid phase obtained after séparation in the three phases may be optionally treated with a heatable roll grinder to reduce particle slze and begin pre-drying. Also, sugar, sugar solution and/or fruit juices may optionally be added to separated cocoa solids before drying to improve flavor development during the drying/roasting process.

[0053] The solid phase obtained after séparation In the three phases may be gently dried and simultaneously roasted at a température of between 55 and 100°C, from the vlewpoirrt of reducing the thermal load and preservlng the health-induclng components preferably at a température selected from between 55 and 70°C under reduced pressure, in order to allow roasted flavors and other aromatics to be collected. If desired, said flavors and other aromatics may be added to the cocoa butter or to the aroma recovery step of the water phase in the further progress of the cocoa bean processing method.

[0054] The method of carrying out the drying/roasting is not particularly limited and may e.g. be accomplished in a drum dryer.

[0055] In a preferred embodiment, the drying/roasting step Is carried out in a mixing device 30 as is disclosed In EP 0 711 505 A1 for chocolaté conching. Said mixing device comprises a cylindrical, tubular body arranged with its axis horizontal and closed at its opposite ends by end plates, and having a coaxial heating or cooling jacket through which, for example, diathermie oil or another fluid is Intended to flow to keep the internai wall of the body at a predetermlned température. The tubular body has an Inlet and outlet openlngs for the solid 35 phase. The outlet opening communicates, by means of a duct, with a device for separating the aroma phase from the dried product. The device further comprises a bladed rotor Is supported for rotation In the tubular body, Its blades being arranged as a hélix and oriented for centrifuging the solid phase being processed and slmultaneously transporting It towards the outlet opening. Using this mixing device advantageously allows the drying/roasting step and the séparation of the roasted flavors and other aromatics to be carried out continuously and also remarkably accelerates the processing of unfermented cocoa beans/nibs up to the préparation of the cocoa powder (dry cocoa matter), resulting in processing durations of less than 20 minutes, typically less than 15 minutes.

[0056] In the above-described cocoa bean/nlb processing methods, acidic components, such as e.g. acetic acid formed or added prior to or during an Incubation of the cocoa beans, or citric acid originating from cocoa pulp and mucilage will be found in the water phase and may thus be convenlently neutrallzed and/or removed by treating the water phase appropriately upon phase séparation.

[0057] The method of removing free acid via the water phase is not particularly limited and may be carried out by any suitable method known in the art. For example, acetic acid may be removed from the water phase by e.g. distillation (e.g. extractive distillation or reactive distillation), extraction (e.g. Ilquld-liquid) extraction, emulsion-type liquid membrane processes, salting out or combinations thereof. Altematively, acid may remaln in the water phase if cocoa aroma and polyphenolic powder are selectively extracted therefrom. As Is illustrated In Fig. 2, free acid and other undesired water-soluble components, such as astringency-inducing and/or bitter iow-molecular polyphenols may be removed from the water phase prior to or during the dearomatisation step, and/or prior to or during the concentration step.

[0056] The neutralization and/or removal of free acid via the water phase has signifîcant advantages over the methods disclosed in prior art, a few of which will be discussed in the following:

[0059] Acid is extracted from the cocoa beans or nlbs via the water phase prior to subjecting the solid phase to a drying/roasting step. Therefore, prolonged drying/roasting and high thermal loads upon the fermented cocoa beans are not required in order to evaporate acid, whereby high contents of aromatic flavors, antl-oxidants, vitamins may be preserved. Also, the duration of the conching process may be significantly reduced.

[0060] Furthermore, since the relatively high costs involved with the use of water and its removal are far outweighed by energy savings due to heating at lower températures and accelerated drying/roasting and conching steps, the ' method according to the présent invention also involves économie advantages when compared to conventional methods for the préparation of chocolaté or chocolate-iike products.

[0061] In addition, In contrast to conventional cocoa product manufacturing, cocoa beans having relatively high acid contents and/or being in varying fermentation stages may be used to produce high-quality cocoa products, such as chocolaté.

[0062] A remarkable advantage of the présent invention is that undesired hydrophilic components (such as bitter and/or astringent low molecular polyphenols (e.g. catechins)) may likewise be removed via the water phase. Thus, undesired levels of astringency and blttemess commonly associated with cocoa products made from unfermented cocoa beans may be easily avoided, even in cases where roasting of the unfermented cocoa beans is entirely omitted.

[0063] It has further been found that the water phase obtained In the decanting step also contalns desired flavors, which may be recovered by subjecting the water phase to a first concentration step to obtain aromatics. Additionally, enhancement of cocoa flavors may be achieved using reverse flow distillation (i.e., to separate flavor compounds and water).

[0064] In an optional second concentration phase, évaporation of excessive water may performed to obtain polyphenolic powder.

[0065] Removal of undesired water may be achieved using évaporation techniques which, when employed, can desirabiy, resuit In water suspended flavor compounds. Moreover, concentrated polyphenols may resuit. In yet still further embodiments, recovered cocoa flavors may be enhanced by reverse flow distillation (e.g., to separate flavor components from water), which Is preferably carrled out under low pressure (less than 300 mbar) and room température in order to minimize the thermal load.

[0066] In general, If there Is microorganism spoilage of cocoa extracted materials (I.e. cocoa butter, cocoa powder, cocoa aroma and polyphenolic concentrate), such material can be deodorized employing a vacuum de-aerator. Moreover, If microorganism contamination occurs, a high pressure treatment such as pascalisation Is possible (e.g., which is désirable because it can preserve aromatic compounds). However, If both microorganism spoilage and contamination occurs, heat treatment and deodorization may be employed. Advantageously, the method according to the présent invention allows a fast processlng of the cocoa beans/nibs, so that growth of microorganisms may be kept at a minimum, however.

[0067] Using the herein described technique(s), unfermented cocoa beans may be efficiently processed to produce désirable, commercially valuabie yields of dried and extracted cocoa powder, cocoa butter with hydrophobie cocoa flavor, hydrophilic cocoa flavor, and polyphenol concentrâtes. Moreover, certain résultant cocoa products retain or contain désirable levels of anti-oxidants and/or vitamins and/or possess more désirable (e.g., less bitter) flavors which, in turn, do not require sugar additions (or, at ieast, high levels or sugar additions) when used in food stuffs.

Construction Kit for Chocolaté or Chocolate-LIke Products [0068] In a second embodiment, a construction kit for chocolaté or chocolate-like products including a plurality of cocoa bean extraction products produced In accordance with method steps set forth in the first embodiment outlined above is provided. In other words, the cocoa product construction kit according to the présent Invention preferably comprises at least two of the polyphenolic powder, cocoa powder, cocoa butter and cocoa aroma extracts obtained by the cocoa bean processing methods as described above. In a preferred embodiment, the cocoa product construction kit according to the présent Invention comprises all of the abovementioned extracts.

[0069] The term chocolate-like product, as used herein, refers to a product which faits Into the legal définition of a chocolaté of at least one country, but not all countries, since it deviates in the type and/or the content range of a component legally definlng chocolaté. The use of cocoa pulp/mucilage for the manufacture of chocolaté may, for example, lead to a déviation from the définition of chocolaté under certain national régulations.

[0070] The construction kit for chocolaté and chocolate-like products according to the présent invention advantageously provides starting materials for a large varlety of highquality cocoa-based products, wherein water-soluble undesired hydrophilic components (such as bitter and/or astringent low molecular polyphenols (e.g. catechins)) hâve been removed while retaining high contents of water-soluble aroma components, polyphenolic components and vitamins of the cocoa beans/nibs and preserving high concentrations thereof due to the low thermal burden.

[0071] Hence, It Is possible to manufacture many variants of nutritionally valuable and tasty chocolaté and chocolate-like products, wherein the typical characteristics of the origin, varlety and vintage of cocoa bean - especlally the primary flavors thereof - are perceptible, without unpleasant acîdity, astringency or bittemess.

[0072] Exemplary methods of manufacturing chocolaté and chocolate-like products, on the basis of the construction kit, or the extracts obtained In the method according to the first embodiment, respectively, will be glven herelnbelow.

Methods for Manufacturing Chocolaté or Chocolate-LIke Products [0073] The plurality of cocoa bean extraction products produced in accordance with method steps set forth In the first embodiment may be used for the préparation of a large varlety of chocolaté products, as will be described in the following third embodiment.

[0074] Fig. 4A illustrâtes an example of a method for the préparation of dark chocolaté and milk chocolaté, wherein the cocoa aroma extracts obtained from dearomatisation of the water phase and/or optionally the roasted cocoa aroma obtained from the drylng/roasting step (as indicated in Fig. 2) are first added to the cocoa butter. Before being subjected to a conchlng step, the dried and roasted solid cocoa powder is mixed with cocoa butter with added aroma and fine milled. Polyphenolic powder may be added to the mixture as desired to provide more intense flavors and higher contents of anti-oxidants in the final product. Additional tailoring of flavor or development of flavor may be performed by adding one or more of sugar, sweetener, cocoa pulp and/or fruit juices. In a preferred embodiment, the pre-processed or unprocessed pulp/mucilage described in further detail above Is added as a natural sweetener. For the préparation of milk chocolaté, milk powder is further added, preferably prior to the mixing step. Optionally, an emulsifying agent (e.g. lecîthin) may be added prior to conchlng to reduce viscosity, control sugar crystallization and the flow properties of chocolaté, and help in the homogeneous mixing of ingrédients. Also, additional ingrédients and flavors, such as e.g. vanilla, rum and so on may be added prior to or during the conching step.

[0075] The conchlng process redlstributes into the fat phase the substances from the dry cocoa that create flavor, while removing unwanted acetic, propionic, and butyric acids from the chocolaté, reducing moisture, and mellowlng the flavor of the product. The température of the conche is controlled and varies depending on the different types of chocolaté (from around 49 ^eC for milk chocolaté to up to 82 °C for dark chocolaté). While being to some degree dépendent on the température, the conchlng duration in conventional chocolaté manufacturing processes generally ranges from 16 up to 72 hours in order to achieve good results. In the method according to the présent invention, the conching duration is preferably less than 16 hours, more preferably less than 12 hours, typically 10 hours or iess. Thus, a loss of désirable aroma characteristics as observed at long conching times does not occur.

[0076] As alternative chocolaté product that may be manufactured by the method of produclng chocolaté according to the présent Invention as indicated In Fîg. 4B, white chocolaté may be mentioned, which is usually a blend of cocoa butter, sugar, miik solids, emuisifier (e.g. lecithln), as well as optionally vanilla for flavor, depending on the producer’s recipe. In a preferred embodiment, the pre-processed or unprocessed pulp/mucilage described in further detail above is added as a natural sweetener instead of sugars.

[0077] Conventional methods for the production of white chocolaté involve the use of deodorized cocoa butter. Specifically, cocoa butter is conventionally prepared by methods comprising the alkalization of cocoa liquor, which contributes to high contents of bitter flavor components in the cocoa butter that hâve to be removed, which may be achieved by means of extraction with organic solvents or steam injection to provîde a low-odor, non-bltter and flavorless cocoa butter basis for the further préparation of white chocolaté. However, such processes are known to Involve a réduction of the contents of vitamlns and anti-oxîdants in the cocoa butter.

[0078] Advantageously, using the herein described techniques, cocoa butter with less bitter flavors may be obtained, so that only gentle cocoa butter processing, if any, is required in order to render it usable for the production of white chocolaté, also leading to a préservation of larger contents of désirable components such as vitamins or anti-oxîdants.

[0079] In addition, by recomblnlng of the cocoa butter with the cocoa aromas and/or roasted cocoa aroma and/or the polyphenolic powder as obtained by the method of the first embodiment according to the desired taste allows to produce a white chocolaté having a characteristic and distinct cocoa flavor.

[0080] A process of manufacturing a chocolaté or chocolate-like product having a cocoa content of 100% is schematically described In Fig. 4C. The scheme basically corresponds that of Fig. 4A, with the exception that all Ingrédients exclusively originate from the cocoa fruit. By the processes described above, it Is possible to manufacture a 100% cocoa product, wherein - unlike known similar products - undesired astringency and bltterness commonly associated with cocoa products made from unfermented cocoa beans is avolded and wherein at the same time favorably high amounts of nutritionally bénéficiai and valuable components of the unfermented cocoa fruit, such as e.g. polyphenols, antioxidants, vitamins are contalned. Last but not least, the final product also makes use of cocoa pulp and comprises valuable nutritional and health-inducing ingrédients originating therefrom, such as polyphenols, antioxidants, vitamins and/or sugars. Also, overly acidic flavour notes originating from the pulp may be reduced as desired via pre-processing of the pulp or via removal of acidic components through the water phase.

[0081] In general, the chocolaté or chocolate-like products obtained by the methods of the présent Invention may take any suitable form and may, for example, be packaged and sold as a block or a bar, be filled and may be used as a coating, be used in other confectionery and bakery applications (e.g. as a cake coating or fiillng, a biscuit coating or filling, a sponge coating or filling or a coating layer for an Ice cream). Also, the obtained chocolaté or chocolate-like products may optionally hâve further additives added prior to the final use of the product.

[0082] Once given the above disclosure, many other features, modifications, and improvements will become apparent to the skilled artisan.

Claims (13)

1. A method for processing unfermented cocoa beans, comprising the steps of:

(a) adding water to said unfermented cocoa beans with or without cocoa pulp and mucilage to form a suspension;

(b) wet grinding said suspension;

(c) subjecting said suspension to a heat treatment at a température of 70^eC or less;

(d) separating the suspension into a water phase (heavy phase), a fat phase (light phase) and a solid phase, said fat phase comprising cocoa butter as a major component and solids and/or water as minor components and said solid phase comprising cocoa powder and water; and (e) separately processing the three phases, which optionally comprises:

separating cocoa butter from the fat phase, separating cocoa powder from the solid phase, and separating cocoa aroma and a polyphenolic powder from at least the water phase, wherein said unfermented cocoa beans are not predried, and wherein said unfermented cocoa beans hâve been subjected to an

Incubation step prior to step (a).

2. The method according to claim 1 wherein the Incubation step comprises adding unfermented cocoa beans to an ethanolic solution at a température of between 10^eC and 70’C for a period of between 2 hours and 10 days, the volume of the ethanolic solution being suffirent to cover the cocoa beans.

3. The method according to claim 2, wherein the éthanol concentration In the ethanolic solution is at least 1 vol.-% and less than 7 vol.-%.

4. The method according to any of the preceding daims, wherein said unfermented cocoa beans are not depulped.

5. The method according to any of daims 1 to 4, further comprising a step of depulping the unfermented cocoa beans prior to step (a).

6. The method according to claim 5, wherein the cocoa pulp and mucilage obtained In the depulping step Is processed separately from the unfermented cocoa beans and subsequently added to the suspension bofore or during steps (a), (b), (c) or (d).

7. The method according to claim 6, wherein the processîng of the cocoa pulp and mucilage comprises neutralizîng and/or removing acidic components.

8. The method according to any of the preceding daims, wherein cocoa aroma and polyphenolic powder are extracted from the water phase and the solid phase.

9. The method according to any of the preceding daims, wherein each of said cocoa processing steps are performed at températures of no more than approximately 70°C.

10. A construction kit for chocolaté or chocolaté-like products, comprising the cocoa butter, cocoa powder, polyphenolic powder and cocoa aroma extracts obtained by the method according to claim 1.

11. A method for producing chocolaté or chocolate-like products comprising the steps of:

(a) adding water to unfermented cocoa beans to form a suspension;

(b) wet grinding said suspension;

(c) subjecting said suspension to a heat treatment at a température of 70°C or less;

(d) separating the suspension Into three phases, i.e. a water phase (heavy phase), a fat phase (light phase) and a solid phase, said fat phase comprising cocoa butter as a major component and solids and/or water as minor components and said solid phase comprising cocoa powder and water; and (e) separately processing the three phases, which comprises:

separating cocoa butter from the fat phase, separating cocoa powder from the solid phase, and separating cocoa aroma and a polyphenolic powder from at least the water phase;

(f) recombining the cocoa aroma extract with the cocoa butter extract;

(g) mixing the recombined extracts with said cocoa powder extract, said polyphenolic powder extract and/or mïlk powder; and (h) conching said mixture.

12. The method according to claim 11, further comprising a step of depulping the unfermented cocoa beans prior to step (a), optionally processing the cocoa pulp and

5 mucilage obtained in the depulping step separately from the unfermented cocoa beans, and subsequently adding the cocoa pulp either to the suspension before or during steps (a), (b), (c) or (d), or before or during steps (f), (g) and (h).

13. A chocolaté or chocolate-like product obtained by the method according to any one of 10 claims 11 or 12.