OA18586A - Cocoa extracts, cocoa products and methods of manufacturing the same. - Google Patents

Abstract

Disclosed is a method for processing cocoa beans or nibs comprising the steps of: (a) adding water to cocoa beans or nibs 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) comprising cocoa butter, and a solid phase comprising cocoa powder and fluid components; (e) continuously separating the fluid components from the solid phase obtained in step (d) to obtain cocoa aroma and cocoa powder by supplying a flow of said solid phase to a mixing device; wherein the mixing device comprises: a cylindrical, tubular body with a horizontal axis having an inlet opening for the solid phase, an outlet opening for the dried solid phase and an optional outlet opening for a vapor phase comprising cocoa aroma; end plates closing the tubular body at its opposite ends; a coaxial jacket heating or cooling the internal wall of the tubular body to a temperature of from 55°C to 150°C; and a bladed rotor, which is supported for rotation in the tubular body, its blades being arranged as a helix and oriented for centrifuging the solid phase and simultaneously transporting it towards the outlet opening.

Description

FIELD OF INVENTION [0001] This Invention relates to Improved methods and techniques for the production of cocoa extracts and chocolaté or chocolate-iike products. In certain embodiments, this invention relates to cocoa bean processing methods using cocoa beans which resuit in 10 cocoa products, chocolaté or chocolate-iike products with improved taste characteristics and/or increased levels of antioxidants and/or vitamins.

BACKGROUND OFTHE INVENTION [0002] Cocoa (Theobroma cacao L) is commonly known as an important source of healthy 15 ingrédients, such as e. g. minerais, vitamins, polyphenols (especlaily catechlns, anthocyanidins and proanthocyanidlns), and antioxidants such as flavonolds, so that a number of methods has been deveioped to Improve the yield of said ingrédients. For example, EP 2 071 961 A1 discioses a method for obtaining polyphenol-rich cocoa powder extracts.

[0003] The types of methods and the steps employed for processing cocoa beans into food products such as e.g. chocolaté hâve a slgnlficant influence on the various qualifies of the resulting cocoa products such as with respect to flavor, Intensity, or anti-oxldant or vitamin content and even yield. For this reason, the method employed for processing cocoa beans into cocoa products (such as food stuffs) can be critically Important to the commercial 25 viability or success or acceptance of such products (in the marketpiace, or In use for enhancement of other products).

[0004] Conventlonally, the processing of cocoa beans Inltially Involves the steps of harvesting cocoa pods, opening the pods to release the cocoa beans, followed by the fermenting and drying of the cocoa beans. Thereafter, the cocoa beans are cleaned, 30 optionally broken into nibs and roasted, whereby the shells of the cocoa bean shelis become brlttle. While roasting conditions are generally selected depending on the variety of the cocoa bean, roasting is usually carried out by subjecting the cocoa beans or nibs to températures of from about 100°C to 160^eC for around 15 minutes (at hlgh températures) to a few hours (at lower températures), such as in the method disclosed In EP 2 273 888 B1, for example. 35 Subsequently, the cocoa beans or nibs are subjected to grinding or mechanical extraction processes, such as the techniques disclosed In WO 03/045159 A1, for example. During these steps, high mechanlcal loads, shear stresses and/or frictional heat lead(s) to a destruction of cellular compartments of the raw cocoa materials, which results In liquéfaction of cocoa fat and émulsification of oll-fat fractions. Usuaily, the resulting cocoa liquor Is then mixed with cocoa butter, sugar, milk or further Ingrédients, dependlng on the Indivldual manufacturées formula, and optionally refined to produce a refined chocolaté paste. Thereafter, the refined chocolaté paste is subjected to conching, e.g. In accordance with the method of continuous conching according to EP 0 711 505 Al. Herein, a chocolaté paste (usuaily comprising cocoa dry matter as weil as cocoa butter, sugar and/or leclthln) refined In accordance with the above-mentioned conventional method is supplied into a mixing device comprising an outlet opening, which is connected by means of a duct with a separator device which séparâtes air and molsture from the processed chocolaté paste. The conched mass Is then tempered under controlled conditions and molded.

[0005] However, such techniques are disadvantageous from the viewpoint of processabillty and recovery of désirable flavors and healthy Ingrédients, since after émulsification during grinding or mechanicai extraction, séparation of the oil-fat phase wlthout the use of undeslrable solvents (such as hexanoi, for example), as well as obtainlng or retaining désirable flavors and/or cocoa products such as aromatics, anti-oxidants, and/or vitamlns is difficult If not impossible. In addition, dry roasting of beans/nibs involves a compromise regarding the yield and quallty of flavor notes, since it is difficult to Identify and monltor roasting conditions under which the flavor within the beans/nibs is fully developed without being decomposed and/or being driven out of the bean and lost with the exhaust gas during roasting.

[0006] WO 2010/073117 A2 discloses an alternative method for processing cocoa beans, which comprises the formation of a suspension comprising cocoa beans or nibs and water, wet grinding the suspended beans or nibs In multiple steps, 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 liquor during mechanlcal processing. Said process employs lower températures and low shear forces, so that improvements In the rétention of nutritionally bénéficiai components and the taste of the resulting cocoa products are achieved.

[0007] However, the use of water as an extraction solvent in the method of WO 2010/073117 A2 involves several challenges. For Instance, during the course of the cocoa bean processing method, large amounts of added water have to be removed again, which may be energy-intensive, especially when drying and/or roasting the solid phase after decanting. Furthermore, since the process is carried out at relatively low températures, the drying step should proceed quickly, continuously and Ideally with a high throughput in order to suppress the growth and/or propagation of microorganisms without requiring extensive steriiization or tyndaliization treatments during the course of the process.

[0006] In this regard, It has been found that the use of conventional drum dryers for drying and/or roastlng of the solid phase obtalned after phase séparation Is problematic, slnce it is difficult to simuitaneously mlnlmlze the thermal burden upon the solid phase (which Is favourable when a high content of whoiesome nutritients, such as e.g. polyphenols and vltamlns Is desired) and effect a development of rich roast and grill flavors and secondary aromas. In particular, drying the decanted solid phase with a drum dryer may require processing tlmes In the order.of severai hours in order to obtain desired ieveis of roast/secondary flavors, which impllcates a high thermal load on the soild phase even If the process Is conducted under sub-atmospheric conditions.

[0009] Accordingly, the provision of methods and products that overcome the above disadvantages Is désirable.

SUMMARY OFTHE INVENTION [0010] The présent invention solves this object with the subject matter of the cialms as defined herein. The advantages of the présent Invention wiii be further explained in détail In the section below and further advantages will become apparent to the skilled artisan upon considération of the invention disclosure.

[0011] Generally speaking, In one aspect the présent Invention provides a method for processing cocoa beans or nibs comprising the steps of: (a) adding water to cocoa beans or nibs to form a suspension; (b) wet grinding said suspension; (c) subjecting said suspension to a heat treatment at a température of 70°C or iess; (d) separating the suspension into: a water phase (heavy phase) comprising aromatic flavors, a fat phase (light phase) comprising cocoa butter, and a solid phase comprising cocoa powder and fluid components; and a solid phase comprising cocoa powder and fluid components; (e) continuously separating the fluid components from the solid phase obtalned in step (d) to obtain cocoa aroma and cocoa powder by supplying a flow of said solid phase to a mixing device, wherein the mixing device comprises: a cylindrlcal, tubuiar body with a horizontal axis having an inlet opening for the solid phase, an outlet opening for the dried solid phase and at least one outlet opening for a vapor phase; end plates closing the tubuiar body at its opposite ends; a coaxial jacket heating or cooling the internai wall of the tubular body to a température of from 55°C to 150’C; and a bladed rotor, which is supported for rotation in the tubular body, its blades being arranged as a hélix and oriented for centrifuging the solid phase and simuitaneously transporting it towards the outlet opening.

[0012] A further aspect of the présent invention is the provision of a method for producing cocoa products, chocolaté or chocolate-like products comprising the steps of: processing cocoa beans or nlbs according to the method defined above, and mixing the obtained cocoa powder with at least one of cocoa aroma, cocoa butter or polyphenolic powder.

[0013] Another aspect of the présent Invention are cocoa products, chocolaté or chocolatelike products obtained by the herein specified methods.

BRIEF DESCRIPTION OF THE DRAWINGS [0014] FIG. 1 schematically illustrâtes the method for processing cocoa beans or nibs according to an embodiment of the subject Invention up to an optional provision of extracts obtained by the separated phases (dashed and dotted Unes represent optional processing steps).

[0015] FIG. 2 schematically Illustrâtes the method for processing cocoa beans or nibs according to a preferred embodiment of the subject Invention up to an optional provision of extracts obtained by the separated phases (dashed and dotted iines represent optional processing steps).

[0016] FIG. 3 schematically illustrâtes a mixing device used for the drylng/separation step(s) In the methods according to the subject Invention.

[0017] FIG. 4 Illustrâtes an exemplary method for preparing dark chocolaté.

[0018] FIG. 5 schematically illustrâtes an exemplary method for preparing dark chocolate/milk chocolaté using the cocoa powder obtained after séparation and processing of the fat, solid and water phases.

DETAILED DESCRIPTION OFTHE INVENTION [0019] For a more complété understandlng of the présent Invention, reference is now made to the foiiowlng description of the Illustrative embodiments thereof:

Method for Processing Fermented Cocoa Beans and/or Nibs [0020] The method for processing fermented cocoa beans or nibs according to the présent Invention Is generally characterized by the steps of: (a) adding water to cocoa beans or nibs 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: a water phase (heavy phase), a fat phase (light phase) comprising cocoa butter, and a solid phase comprising cocoa powder and fluid components; (e) continuously separating the fluid components from the solid phase obtained in step (d) to obtaln cocoa aroma and cocoa powder by supplying a fiow of said solid phase to a mixing device; wherein the mixing device comprises: a cylindrlcal, tubular body with a horizontal axis having an inlet opening for the soiid phase, an outlet opening for the dried solid phase and an optional outlet opening for a vapor phase comprising aromatics; end piales closing the tubular body at its opposite ends; a coaxial jacket heating or cooling the Internai wall of the tubular body to a température of from 55^eC to 150°C, preferably to a température of from more than 65^eC and less than 140^eC; and a bladed rotor, which Is supported for rotation In the tubular body, its blades being arranged as a hélix and oriented for centrifuging the solid phase and simultaneously transporting It towards the outlet opening. It has been found that said method provides enhanced heat transfer to the solid phase and aiiows advantageously rapld, gentle, continuous and high-throughput drying/roasting of the cocoa powder.

[0021] FIG. 1 schematlcally Illustrâtes the method for processing cocoa beans or nibs up to an optional provision of extracts obtalned by the separated phases.

[0022] The pre-treatment of the cocoa beans or nlbs used for the processing method of the présent invention is not particularly limited. Thus, the cocoa beans or nlbs may be unfermented, underfermented, fermented, and/or Incubated according to techniques known In the art or green beans with or wtthout cocoa puip/mucllage may be used freshly after séparation from the pod.

[0023] The subject cocoa processing technique generally beglns wtth forming a suspension of cocoa beans or nlbs by adding water according to step a) either prior or during the grinding of the cocoa beans/nibs.

[0024] 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, which may advantageously affect the processabllity In the further steps (e.g. faciiitated pumping, grinding and easier phase séparation).

[0025] If désirable from the viewpoint of introducing additional flavors, alternative water· containing liquids may aiso 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 exemple, in such a case, it is préférable that the water content In the formed suspension fails Into the above-defined ratios. Since the thermal load in the further method steps is relatively low, temperature-sensitive flavors originating from said liquids are retalned and may favorably Internet with the primary and secondary flavors of the cocoa bean.

[0026] In ordar to obtain coffee-flavored cocoa products, coffee beans (whole or broken, unroasted or roasted) may be mixed to the cocoa beans/nibs when forming the suspension in watar, 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 miliing 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.

[0027] In step b) the cocoa beans/nibs are subjected to a single or multiple wet grinding _çstep(s), which resuit In bean particle sizes of preferably 50 pm or smailer, more preferably 40 pm or smailer, even more preferably 20 pm or smailer. Reducing the bean partlcles to such a size range substantially increases the exposed surface area of the bean particle material therefore aliowing It to be more efficlently wet (e.g., with water rather than a chemical solvent) for improved extraction results (such as improved extraction of fats or ilpids, aromatic substances, and/or polyphenols). The bean particle size réduction may be accompilshed by using dise mllls (e.g. perforated dise mill), col loi d mills (e.g. toothed colloid mi lis), or corundum stone mills, for example. It is préférable that in at least one grinding 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 the product of the wet milling method Is not emulsified. For example, when using multiple grinding steps, a coarse wet grinding 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 colloid mill for a fine grinding step.

[0028] After the wet grinding step (b), the suspension is subjected to a thermal treatment at a . température of no more than approximately 70^eC in order to reduce the overall thermal load and prevent émulsification (step (c)). From the viewpoint 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^eC are préférable. In terms of cocoa butter liquéfaction and/or improved mechanical phase séparation, a heating température range of from 45 to 50^eC Is particulariy préférable. Without being limited thereto, heating of the wetmilied suspension may be carried out by a scrap or tube heat exchanger.

[0029] Thereafter, phase séparation Is carried out In step (d) so that three phases, I.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 ma|or component and solids and/or water as minor components, and said water phase comprising water and aromatic flavors. The solid phase comprises cocoa powder and fiuid components. The cocoa powder may comprise residual cocoa butter In a content of up to 30% by weight, preferably less than 27% by weight, more preferably less than 20% by weight relative to the total weight of the cocoa powder. The term fluid components used herein dénotés residues of specles remaining In the solid phase after phase séparation in step (d) that are fluid at room température, such as an aqueous phase (which may comprise hydrophillc polyphenols and aromatic flavors, for example) and volatile compounds.

[0030] Preferably, devices employing centrifugal forces may be utilîzed to achieve mechanical particle 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 particies may be further separated from liquids and/or oil 5 products may be separated from non-oil products.

[0031] 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 remainlng fine particies or water from the fat phase - - ·_ and the thus obtained fine particies and water may be recombined with the water and solid phases from the Initial decanting step or at a later processing stage of said phases. Also, the water phase may be subjected to further purification steps, e.g. by filtration using vacuum rotation filters in order to reduce cloudiness of the liquid and to remove fine particies, which may be then recombined with the solid phase.

[0032] Upon séparation of the three phases (l.e. the water phase (heavy phase), the fat phase (light phase) and the soiid phase), these may be Independently processed to separate cocoa butter (from the fat phase) and a polyphenolic concentrate (from the water phase), as Is illustrated by Fig. 1.

[0033] The cocoa bean/nib processing method described herein further has the advantage 20 that undeslred acids (such as e.g. acetic acid formed during fermentation or formed or added prior to or during an Incubation of the cocoa beans) leading to a sour or bitter taste In the final product or further hydrophilic components (such as bitter and/or astringent low molecular polyphenols (e.g. catechins)) may be removed via the water phase. The method of removing such undesired components is not particularly limited and may be carried out by 25 any suitable method known In the art. For example, acids may be removed from the water phase by e.g. distillation (e.g. extractive distillation or reactive distillation), extraction (e.g. liquid-liquid) extraction, emulsion-type liquid membrane processes, salting out or combinations thereof. Removing the undesired hydrophilic components prior to subjectlng the solid phase to a drying/roasting step fs advantageous over conventlonal processes 30 known In the art in that proionged drying/roasting and high thermal loads upon the fermented cocoa beans (especially during roasting and conching) are not requlred In order to evaporate or décomposé the components, so that high contents of aromatic flavors, antl-oxldants, vltamins may be preserved. Also, cocoa beans having relatively high acetic acid contents and/or being in varying fermentation stages may be used to produce high-quality cocoa 35 products, such as chocolaté. Moreover, the less bitter flavor profile of the résultant products does not require extensive addition of sugar or sweeteners to mask or compensate for the bitter taste.

[0034] Dried cocoa powder Is obtained from the solid phase exltlng the separator In step (e) of the presently clalmed method. Cocoa aroma extract may be obtained through processing (e.g. concentrating) of the water phase and from the vapor phase exiting the separator In step (e).

[0035] As Indicated above, the fat phase (light phase) may be filtered (e.g. by empicying a vibrating screen) and/or conveyed to a 3-phase separator (e.g. centrifuge) to remove fine partlcles (which may be optionally added to the solid phase prior or during the drylng/roastlng step) and residue water (which may be optionally added to the water phase prior to aroma recovery). Cocoa butter Is obtained by filtering the purified fat phase. --- _,x. .

[0036] The (wet) solid phase obtained after séparation In the three phases may be optionally- v treated with a heatable roll grinder to reduce partiels size and begln pre-drying, Also, sugar, sugar solution and/or fruit juices may optionally be added to separated cocoa sollds before drying to Improve flavor development during step (e).

[0037] In accordance with the présent Invention, the (wet) solid phase obtained after séparation In the three phases Is dried and/or roasted in a single or multiple steps In parallel or In sérias, preferably In sériés, by continuously separating the fluid components from the solid phase obtained in step (d), which Is effected by supplying a flow of said solid phase to one (or more) mixing device(s). Said mixing device, a schematlc représentation of which is depicted in Ag. 3, comprises: a cyllndrical, tubular body (1) with a horizontal axis (2) having an Inlet opening (3) for the solid phase, an outlet opening (4) for the dried solid phase and an optlonal outlet opening (10) for the vapor phase; end plates (5, 5') closing the tubular body at Its opposite ends; a coaxial jacket (6) heating or cooling the Internai wall (7) of the tubular body to a température of from 55°C to 150°C, preferably to a température of from more than 65°C and less than 140“C; and a bladed rotor (8), which Is supported for rotation in the tubular body (1), Its blades (9) being arranged as a hélix and oriented for centrifuging the solid phase and simultaneously transporting it towards the outlet opening (4). While not being particularly limited, It Is preferred that diathermie -oil or another fluid Is used as a heating medium within the coaxial jacket (6) In order to keep the Internai wall (7) of the body at a predetermlned température.

[0038] During rotation of the bladed rotor (8), centrifugai forces resuit In formation of a thin, dynamic, tubular layer of the solid phase on the Inner wall (7) of the tubular body, while the interaction of the solid phase with the blades (9) simultaneously mixes and advances the thln layer of the solid phase towards the outlet opening (4). Thus, effective heat exchange between the heated Inner wall and the solid phase is achieved, which In combination with the mixing, requires relatlvely low heating températures and thereby results In a fast and gentle drying and roasting of the solid phase, so that In comparison with drying using conventional continuously or batch operated drum dryers, the solid phase retalns higher concentrations of polyphenols (especially catechlns, anthocyanldins and proanthocyanidîns), antloxldants and/or aromatic flavors. Moreover, It has been surprisingiy found that after drylng and roasting using of the mixlng device in step (e) for less than 10 minutes, typically less than 5 minutes, under conditions where the product température does not exceed 90°C, the overall 5 concentration of roast and grill flavors (such as e.g. furan-2-carbaldehyde, 1-(2-furanyl)ethanone, benzaidehyde, 5-methyl furfural, 2-furanmethanol, phenylmethanol, and/or 4methylphenol) In the resulting cocoa powder and cocoa aroma Is higher than after drying with a convention al drum dryer under sub-atmospherlc pressure for several hours (typically about 10 hours) using a linear température gradient of from about 65 to100°C.Thus, beslde of the 10 accélération of the drying/roastlng process, the presently clalmed method reduces the thermal stress on the solid phase, so that - In contrast to conventional drylng/roasting slmultaneously higher concentrations of roast flavors and higher overall contents of primary flavors, polyphenols, antloxldants and/or vitamins may be retalned In the resulting extracts and final products.

[0039] Using the device described above advantageously allows the drylng/roasting step and the séparation of the roasted flavors and other aromatics to be carried out continuously and also remarkably accelerates the processing of cocoa beans up to the préparation of the cocoa powder (dry cocoa matter), resulting In overall processing durations forsteps (a) to (e) of less than 20 minutes, typically iess than 15 minutes, which Is a remarkabie Improvement 20 over the prior art and Involves économie advantages when compared to conventional methods for the préparation of cocoa products.

[0040] In general, If there Is mlcroorganlsm spoilage of cocoa extracted materials (Le. cocoa butter, cocoa powder, cocoa aroma and polyphenolic concentrâtes such material can be deodorized employing a vacuum de-aerator, a high pressure treatment such as pascalisation 25 Is possible. However, since the method according to the présent Invention allows an advantageously fast processing of the cocoa beans/nibs, contamination with and growth of mlcroorganisms may be ruled out or kept at a minimum.

[0041] As Indicated above, the mlxing device comprises an outlet (10) for a vapor phase (I.e. the vapors generated during the drying of the solid phase) which may serve several 30 p urposes, depending on Its composition and température.

[0042] Preferably, a flow of hot air Is supplied via optional Inlet (11) to the mlxing device slmultaneously and concurrently with the flow of the solid phase to be dried, In order to enhance the heat distribution and drylng of the solid phase Inside the tubular body (1) and to drive the vapor phase towards the outlet (10).

[0043] In a preferred embodiment, the vapor phase exiting the mlxing device is fed Into the suspension before or during steps (b) or c), more preferably before or during step (b). Refeeding the hot vapor phase accordlngly contributes to or effects (pre-)heating of the suspension to the desired températures In step (c) by heat-exchange. Thereby, the energy expense required for step (c) may be effectiveiy reduced, leading to a cocoa bean processing method with improved energy-efficiency. In addition, the phase séparation In step (c) is Improved. A further advantage is that aromatlc flavors contalned in the vapor phase are retained in the system, and may be further incorporated into each of the three phases In the step (d), so that an optimum yield of those components in the final extracts or products is ensured. Said embodiment will usually be preferred If the vapor phase contains relatively low amounts of aromatic flavors, such as e.g. roast aromas.

[0044] In a further préférable embodiment,.which Is especlally advantageous If the vapor phase contains relatively high amounts of aromatlc flavors, especlally roast and grill flavors, the vapor phase exitlng the mixing device in step (e) Is collected as aroma phase, which may be optionally further processed by separating the flavor components to obtain cocoa aroma.

[0045] Albeit not necessary, It is practical to combine the collected aroma phase with the water phase obtained in the phase séparation step (d), since the latter also contains désirable flavors, and to subject the combined liquids to a first concentration step to obtain cocoa aroma. in yet stili further embodiments, recovered cocoa flavors may be enhanced by reverse flow distillation (e.g., to separate flavor components from water), which is preferably carried out under low pressure (less than 300 mbar) and room température in order to minimlze the thermal load. After séparation of cocoa flavors/aroma from the combined liquid, évaporation of excessive water may performed In an optional second concentration step to obtain polyphenolic powder. Removal of undesired water may be achleved by using évaporation techniques which, when employed, can desirably, resuit In water suspended flavor compounds and concentrated polyphenolic powder, respectîvely.

[0046] By using multiple mixing devlces according to the above description In parallel, It Is possible to combine the latter advantages, so that the vapor phase exiting one mixing device, which Is preferably operated at relatively low internai wall heating températures, may be fed into the suspension before or during steps (b) or (c), more preferably before or during step (b), and the vapor phase exiting another device, which is preferably operated at relatively high Internai wall heating températures, may be collected as aroma phase for aroma recovery.

[0047] In a preferred embodiment of the présent Invention, which is schematlcaily illustrated In Fig. 2, step (e) comprises two substeps, namely: (e1) continuously pre-dryfng the solid phase obtained In step (d) by suppiying a flow of said solid phase to a first mlxing device; and (e2) continuously drying the pre-drled solid phase obtained in step (e1) by suppiying a continuous fiow of the pre-drled solid phase to a second mixing device; wherein each of the first and second mlxing devices comprise: a cyllndrical, tubuiar body (1) with a horizontal axis (2) having an iniet opening (3) for the solid phase, an outlet opening (4) for the dried solid phase and at least one outlet opening (10) for exhaust vapors; end plates (5, 5') closing the tubular body at Its opposite ends; a coaxial jacket (6) heating or cooling the Internai wall (7) of the tubular body to a température of from 55’0 to 150°C; and a bladed rotor (8), which is supported for rotation ln the tubular body (1), Its blades (9) being arranged as a hélix and orlented for centrifuging the solid phase and simultaneously transporting it towards the outlet opening (4). ln other words, the first and second mixing devices both exhiblt the characteristics of the mixing device described initially above. Conducting the drying/roasting process in said manner results In an excellent balance of drying performance, process and energy efficiency, development of roast flavors and high yield of primary flavors, polyphenols, antioxldants and/or vitamins. [0048] Preferably, the first and second mixing devices are operated under different conditions (e.g. Internai wall heating températures, vapor phase outlet connection) or exhiblt different dimensions. More preferably, the internai wail heating température of the first mixing device is lower than the Internai wall heating température of the second mixing device.

[0049] Preferably, the internai wall of the tubular body of the first mixing device is heated to a température of between 70 and 110’C, preferably between 80 and 100“C. ln a more preferred embodiment, the température of the internai wall (7) of the tubular body of the first mixing device in the pre-drying step (e1) is heated so that the température of the pre-dried solid phase exlting the outlet (4) is between 70 and 100’C, more preferably between 80 and 90^eC.

[0050] In a preferred embodiment, the first mixing device is operated under conditions where the pre-dried solid phase obtained after step (e1) has a water content of 3 to 7% by weight, more preferably 4 to 6% by weight.

[0051] It is further preferred that the vapor phase exlting the first mixing device is fed into the suspension before or during steps (b) or (c), more preferably before or during step (b).

[0052] Preferably, the internai wall of the tubular body of the second mixing device is heated to a température of between 100 and 150^qC, preferably 120 to 145’C. More preferably, the température of the internai wall (7) of the tubular body of the second mixing device ln the drying step (e2) Is heated so that the température of the solid phase exlting the outlet (4) is between 110 and 145^eC, more preferabiy between 120 and 135^eC.

[0053] It is further preferred the vapor phase exlting the second mixing device ln step (e2) is collected as aroma phase for aroma recovery.

[0054] ln a preferred embodiment, the second mixing device Is operated under conditions where the solid phase obtained after step (e2) has a water content of less than 3% by weight, more preferably less than 2% by weight, even more preferably less than 1% by weight.

[0055] In general, it Is préférable that in the mixing device(s) used In step (e) or any of the substeps (e1) and (e2), the bladed rotor(s) Is driven at a speed of from 300 to 1300 rpm, more preferably between 700 and 1100 rpm, further preferably between 800 and 1000 rpm.

[0056] In a preferred embodiment, the duration of step (e) (or the duration of the sum of substeps of step (e)) Is shorter than 15 minutes, more preferably shorter than 10 minutes, In order to prevent prolonged exposure of the (pre-dried) solid phase to eievated températures.

Cocoa Powder Extract [0057] In a second embodiment, the présent Invention relates to cocoa powder produced in accordance with method steps set forth in the first embodiment outlined above. This extract représente a staring material for a large variety of hlgh-quaiity chocolaté products, wherein high concentrations of water-solubie aroma components, polyphenolic components and vitamins of the cocoa beans/nibs and preserved in high concentrations due to the low thermal burden, while water-solubie undesired hydrophilic components (such as acids or bitter and/or astringent iow molecular polyphenols (e.g. catechins)) hâve been optionally removed.

[0058] The dried cocoa powder prepared by the method of the présent invention typically exhibits a water content of less than 2 % by weight, usually less than 1.5% by weight and a fat content of typlcaily 30% by weight or less, preferably less than 27% by weight or less, more preferably less than 20% by weight, each based on the total weight of the dried cocoa powder.

[0059] As has been found by GC-MS analysis of the fiavor components, the dried cocoa powder obtained by the presently claimed method comprise a higher total concentration of raw/earthy, fruity/flowery, maity/buttery, and griiled/roasted aromas, and a lower concentration of stinging/acidic flavors when compared to commercîally available cocoa powder.

[0060] For the purpose of quantïfying the aroma profile, cocoa powder, cocoa aroma, polyphenolic powder and cocoa butter extracts hâve been produced In accordance with the exemplary scheme illustrated by Fig. 4, wherein the drying/roastlng step has been carried out by using a mixing device in accordance to the above description. Overall, Fig. 4 shows an exemplary method of processing cocoa beans from the non-roasted bean to the préparation of a chocolaté product.

[0081] The abovementioned fiavor types hâve been quantified In the extract obtained by the presently claimed method and a commercîally available cocoa powder. Speclfically, the raw/earthy flavors hâve been quantified via GC-MS by the total concentration of pyrazine dérivatives (i.e. 2-acety!pyrazine, methylpyrazine, tetramethylpyrazine, 2,3-dimethylpyrazine,

2,6-dimethylpyrazine, 2,5-dimethyipyrazine, trlmethylpyrazine, ethylpyrazine, 2-ethyl-3 methylpyrazine, 2-ethyl-6-methylpyrazine, 2-ethyl-5-methylpyrazine, 2-ethyl-3,6dimethylpyrazine, 2-ethyl-3,4-dimethylpyrazine₁ 2,3-diethyi-5-methylpyrazine, 2-lsopropy1-3methoxypyrazine and 2-isobutyl-3-methoxypyrazine); the fruity/flowery flavors hâve been quantifled by the total concentration of 1-methyf-IH-pyrroie, ethyl-2-methyl butanoate, 3methylbutyl acetate, 2-heptanone, hexyl acetate, linaool, benzyl alcohol, 2-phenylethanol, ethyl cinnamate, 2-phenethy! acetate; the malty/buttery flavors hâve been quantifled by the total concentration of vanillin, isobutanal, 2-methyl butanal, Isovaleradehyde, acetoin and butane-2,3-dlone; the grilled/roasted flavors hâve been quantifled by the total concentration of furfural, 2-acetylfurane, benzaldehyde, 5-methylfurfural, 2-furanmethanol, benzyl alcohol,

4-methylphenol; and the stlnging/acidic flavors hâve been quantifled by the total concentration of acetic acid, propionic acid, Isobutyrlc acid, 2-methylbutyric acid, 3methylbutanoic acid, and pentanolc acid. The results of the measurements are shown In Table 1.

[0062] TABLE 1

Fiavor type	Concentration In cocoa powder [mg/kgj
Invention	Comparative Example
raw f earthy	1.066	0.728
frulty / flowery	1.962	2.695
maity / buttery / roasty	7.132	4.081
stingy / addic	40.05	100.20

[0063] Table 1 shows that the total content of flavors that are perceived as pleasant Is substantially higher in the cocoa powder obtained by the method of the présent Invention (10:180 mg/kg) when compared to conventional cocoa powder (7.504 mg/kg), while the concentration of stingy/acidlc flavors Is remarkably lower, since a large fraction thereof Is extracted via the water phase.

[0064] The total polyphenoi content of the defatted cocoa solid is typically at least 40 mg of ECE (epicatechin équivalents) per gram of defatted dry mass, preferably more than 50 mg of ECE per g of defatted dry mass, further preferably more than 55 mg of ECE per g of defatted dry mass. The total polyphenoi content may be determined by using a Folin-Ciocalteu assay with (-)-epicatechin as standard, in accordance with the method disclosed in Folin-Ciocalteu Index, Off. J. Eur. Communities 1990, 41, 178-179, and Cooper et al., J. Agric. Food Chem 2008, 56, 260-265.

[0065] It has been found that by use of conventional drum dryers Instead of the mixing device described above, the combination of the abovementioned properties cannot be achleved since the prolonged heating durations required for the development of the same concentrations of grill/roast fiavors lead to a substantial loss or décomposition of polyphenols, antioxidants and/or vitamins.

[0066] In the cocoa aroma produced In accordance with method steps set forth In the first embodiment outlined above, the stinging/acldic fiavors (i.e. the total concentration of acetlc acid, proplonlc acid, isobutyric acid, 2-methylbutyric acid, 3-methylbutanoic acid, and pentanoic acid) typically make up less than 7%, preferably less than 5% by weight based on . the total content by weight of raw/earthy, fruity/flowery, malty/buttery, grilled/roasted and stinglng/acidlc fiavors represented by the marker compounds set out above.

[0067] In a preferred embodiment, the cocoa aroma Is preferably obtained by collecting the vapor phase obtained In step (e2) as aroma phase, comblnlng said aroma phase with the water phase, and subjecting the combined liquid to one or more concentration step(s).

[006Θ] Exemplary methods of manufacturlng chocolaté and chocolate-like products on the basls of the extracts obtained In the method according to the first embodiment, respectively, will be glven herelnbelow.

Methods for Manufacturino Cocoa Products. Chocolaté or Chocolate-LIke Products [0069] The cocoa powder produced in accordance with method steps set forth In the first embodiment may be used for the préparation of a large variety of cocoa products, chocolaté or chocolate-like products, as will be described In the followlng third embodiment.

[0070] The method for producing chocolaté or chocolate-like products according to the présent invention generally comprises the steps of: processing cocoa beans or nibs according to the first embodiment described above; mixing the obtained cocoa powder with at least one of cocoa aroma, cocoa butter or polyphenolic powder; and conching said mixture.

[0071] 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 ail countrîes, since it deviates In the type and/or the content range of a component legally definlng chocolaté.

[0072] Fig. 5 Illustrâtes an example of a method for the préparation of dark chocolaté and milk chocolaté, wherein cocoa aroma obtained from the step (e) or (e2) (optionally together with the product obtained by dearomatlsatlon of the water phase) are first added to the cocoa butter. Before being subjected to a conching step, the dried and roasted cocoa powder obtained from the step (e) or (e2) are mixed with the cocoa butter with added aroma and fine milled. Polyphenollc powder may be added to the mixture as desired to provide more Intense fiavors and even higher contents of anti-oxîdants In the final product. Additional talloring of flavor or development of flavor may be performed by addlng one or more of sugar, sweetener, cocoa pulp and/or fruit julces. For the préparation of milk chocolaté, milk powder is further added, preferably prior to the mixing step. Optionaliy, an emulsifying agent (e.g. lecithin) may be added prior to conching to reduce viscosity, control sugar crystallization and 5 the flow properties of chocolaté, and help in the homogeneous mixing of ingrédients. Also, additional Ingrédients and fiavors, such as e.g. vanilla, rum and so on may be added prior to or during the conching step.

[0073] The conching process redistributes into the fat phase the substances from the dry cocoa that create flavor, while removing unwanted acetic, propionic, and butyric acids from 10 the chocolaté, reducing moisture, and meliowing the flavor of the product. The température of the conche Is controlled and varies depending on the different types of chocolaté (from around 49 °C for milk chocolaté to up to Θ2 °C for dark chocolaté). While being to some degree dépendent on the température, the conching duration in conventlonal chocolaté manufacturing processes generally ranges from 16 up to 72 hours In order to achieve good 15 results. in the method according to the présent invention, the conching duration le preferably less than 16 hours, more preferably less than 12 hours, typically 10 hours or less. Thus, a ioss of désirable aroma characteristics as observed at long conching times does not occur. In addition, since undesired acids may be removed from the product via the water phase, a meliow taste Is achieved In short conching durations.

[0074] Overail, chocolaté or chocoiate-like products obtalned by the methods of the présent invention exhibit favourable organoleptic properties and comprise both high concentrations of roast flavors and higher overail contents of primary flavors, polyphenols, antioxidants and/or vitamine.

[0075] As an example, the polyphenol contents of cocoa beans, a (wet) solid phase and a 25 dark chocolaté obtalned by the method illustrated In Fig. 4 hâve been analyzed by spectrophotometric methods. Specifically, the total polyphenol content has been determined by using a Foiin-Ciocalteu assay with (-)-epicatechln as standard, In accordance with the method disclosed In Folin-Clocalteu Index, Off. J. Eur. Communities 1990, 41,178-179, and Cooper et al., J. Agric. Food Chem 2008, 56,260-265. The total flavonold content has been 30 determined by means of an aluminum chloride colorimétrie assay in accordance with Emeida et al. Int. J. ChemTech Res. 2014, 6(4), 2363-2367, using (-)-epicatechln as standard. An acld-butanol method (such as e.g. Bates-Smith assay or a Porter method) using procyanldin B2 as standard has been employed to spectrophotometrlcally détermine the content of proanthocyanidine. The results are given In Table 2.

[0076] TABLE 2

	raw cocoa beans (non-roasted)	raw cocoa beans (roasted)	solid phase after phase séparation	chocolaté product
total polyphenol concentration (mg ECE7 g defatted dry matter)	84.1 ± 2.7	84.4 ±1.3	60.4 ±2.7	23.5 ± 0.8
flavonoid concentration (mg ECE/ g defatted dry matter)	57.8 ± 2.9	40.8 ±1.8	37.2 ±2.4	14.1 ± 0.3
proanthocyanidlne concentration (mg PCE**/ g defatted dry matter)	7.0 ± 0.8	5.2 ±0.1	5.5 ±0.1	1.8 ±0.2

ECE = (-) epicatechîn équivalents ·· PCE* procyanldln B2 équivalents ' ' 1-. - / [0077] It Is shown that the methods of the présent Invention ensure that the high contents of polyphenols, flavonolds and/or proanthocyanldines présent In the cocoa beans are preserved Inter alia through the solid phase/cocoa powder, so that beside of the favourable aroma profile, optimum yields of healthy Ingrédients may be obtained In the final chocolaté product.

[0076] The chocolaté or chocolate-ilke 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 filling, 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 additlves added prior to the final use of the product.

[0079] Once given the above disclosure, many other features, modifications, and Improvements will become apparent to the skilled artisan.

[0080]

Reference numérale cyllndrical tubular body horizontal axis solid phase inlet opening dried solid phase outlet opening

5,5* end plates coaxial jacket

Internai wall of tubular body bladed rotor blade(s) vapor phase outlet opening hot air Inlet opening heating/cooling medium inlet opening heating/cooling medium outlet opening motor

Claims (11)

1. A method for processing cocoa beans or nlbs comprising the steps of:

(a) adding water to cocoa beans or nibs 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:

a water phase (heavy phase), a fat phase (light phase) comprising cocoa butter, and a solid phase comprising cocoa powder and fluid components;

(e) continuously separating the fluid components from the solid phase obtained In step (d) to obtain cocoa aroma and cocoa powder by supplylng a flow of said solid phase to a mixing device;

wherein the mixing device comprises: a cylindrical, tubular body (1) with a horizontal axis (2) having an Inlet opening (3) for the solid phase, an outlet opening (4) for the dried solid phase and an optlonal outlet opening (10) for a vapor phase comprising cocoa aroma; end plates (5,5') closing the tubular body (1) at Its opposite ends; a coaxial jacket (6) heating or cooling the Internai wall (7) of the tubular body (1) to a température of from 55^eC to 150’C; and a bladed rotor (8), which Is supported for rotation In the tubular body, Its blades being arranged as a hélix and oriented for centrifuging the solid phase and slmultaneously transporting It towards the outlet opening.

2. The method for processing cocoa beans or nlbs according to claim 1, wherein the vapor phase exiting the mixing device Is fed Into the suspension before or during steps (b) or (c).

3. The method for processing cocoa beans or nlbs according to claim 1 or 2, wherein the Internai wall (7) of the tubular body (1) of the mixing device is heated to a température of between 65 and 140*C.

4. The method for processing cocoa beans or nibs according to any of the preceding claims, wherein the solid phase obtained after step (d) has a water content of 50 to 75% by weight.

5. The method for processing cocoa beans or nibs according to any of the preceding claims, wherein step (e) comprises the steps of:

(e1) continuously pre-dryïng the solid phase obtained In step (d) by supplying a flow of said solid phase to a first mixing device; and , (e2) continuously drying the pre-dried solid phase obtained In step (e1) by supplylng a continuous flow of the pre-dried solid phase to a second mixing device;

wherein each of the first and second mixing devices comprise: a cylindrical, tubular body (1) with a horizontal axis (2) having an Inlet opening (3) for the solid phase, an outlet S opening (4) for the dried solid phase and an optionai outlet opening (10) for a vapor phase comprising cocoa aroma; end plates (5,5’) closing the tubular body (1) at its opposite ends; a coaxial jacket (6) heating or cooling the Internai wall (7) of the tubular body (1) to a température of from 55°C to 150°C; and a bladed rotor (8), which Is supportad for rotation In the tubular body, its bladas being arranged as a hélix and orianted for centrrfuging the solid 10 phase and simultaneously transporting It towards the outlet opening.

6. The method according to claim 5, wherein the internai wall (7) of the tubular body (1) of the first mixing device Is heated to a température of between 70 and 110^eC, preferably between 80 and 100’C, and/or wherein the Internai wall (7) of the tubular body (1) of the

15 second mixing device Is heated to a température of between 100 and 150°C, preferably 120 to 140^pC.

7. The method for processing cocoa beans or nibs according to any of the preceding claims, wherein a flow of hot air Is supplied via an Inlet opening (11) to the mixing device(s)

20 simultaneously and concurrently with the flow of the solid phase to be dried.

8. The method for processing cocoa beans or nibs according to any of the preceding claims, wherein the bladed rotor of the mixing device(s) Is driven at a speed of from 600 to 1100 rpm, preferably between 750 and 1050 rpm.

9. The method for processing cocoa beans or nibs according to claims 5 to 8, wherein the first vapor phase exiting the first mixing device In step (e1) Is fed into the suspension before or during steps (b) and (c).

30 10. The method for processing cocoa beans or nibs according to claims 5 to 9, wherein the pre-dried solid phase obtained after step (e1) has a water content of 3 to 7% by weight, and/or wherein the cocoa powder obtained after step (e2) has a water content of less than 3% by weight.

35 11. The method for processing cocoa beans or nibs according to claims 5 to 10, wherein the vapor phase obtained in step (e2) Is collected as aroma phase, said aroma phase Is combined with the water phase, and the combined liquid Is subjected to one or more concentration step(s) to obtain a cocoa aroma extract.

12. Cocoa powder prepared by the method according to any of daims 1 to 11.

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

processing cocoa beans or nibs according to any of clalms 1 to 11, mixing the obtained cocoa powder with at least one of cocoa aroma, cocoa butter or polyphenolic powder; and

10 conchlng said mixture.

14. Chocolaté or chocolate-like products obtained by the method according to claim 13.