OA18587A

OA18587A - Cocoa fruit processing methods and cocoa products obtained by the same

Info

Publication number: OA18587A
Application number: OA1201800013
Authority: OA
Inventors: Tilo HÜHN
Original assignee: Odc Lizenz Ag
Priority date: 2015-07-08
Filing date: 2016-07-08
Publication date: 2018-12-28

Abstract

Disclosed is a method for processing cocoa fruits, comprising the steps of: (a) adding water to 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; wherein the cocoa beans are nondepulped; or wherein cocoa pulp contained in cocoa fruits are separated from the cocoa beans in a depulping step, processed separately from the cocoa beans, and subsequently added to the suspension before or during any of steps (a), (b), (c), or (d). 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 FRUIT PROCESSING METHODS AND COCOA PRODUCTS OBTAINED BY 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 cocoa fruits, wherein the products exhibit reduced acidity, 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, vitamins and/or sugars.

[0002] In certain embodiments, this invention relates to the processing of cocoa beans and cocoa pulp 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, vitamins 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, vitamins, polyphenols (especially catechlns, anthocyanidins and proanthocyanîdins), and antioxidants such as flavonoids, which are Inter alîa physiologically active In the réduction of oxidative stress, Inhibition of low-density lipoproteins (LDL) oxidation and platelet aggregation, and are acting as vasodilators in blood vessels.

[0004] Despite of the importance of cocoa as an agricultural export commodity, normally only about 10% of the gross weight of cocoa pod are utilized for cocoa powder and cocoa butter production, and the main fraction of the total pod weight is discarded as cocoa waste. Therefore, efforts hâve been made in the past to also convert the husk and seed pulp Into bénéficiai by-products in order to commercialize new products which do not interfère with the seed crop.

[0005] In this regard, particular attention has been drawn to aromatic cocoa pulp and mucilage surrounding the cocoa seeds, since these constituées contain high amounts of polyphenois, antioxidants, flavonoids and minerais, along with the main constituées water (80-90%), sugar (10-15%) and citric acid (0.4-2.0%). Cocoa pulp is generally rich in fermentable sugars, such as glucose, fructose and sucrose, and has a low pH of 3.0-3.5, mainly because of the presence of citric acid, making it a suitable medium for microbial growth. For this reason, cocoa pulp is conventionally used to assist fermentation of cocoa beans, during which the pulp becomes liquid and drains away. However, it would be désirable to provide cocoa products which combine the nutritionally bénéficiai ingrédients of the cocoa pulp and mucilage with those contained in the bean, and wherein the flavour note 5 of the pulp is matched well with the taste characteristics of the bean, for example by reducing the acidic flavor note originating from the pulp to a pleasant degree.

[0006] Undesirably high acid concentrations are not only observed in cocoa pulp but also within the cocoa beans during processing. A typical cocoa bean processing procedure begins with the harvest of the cocoa pods, followed by carefu! 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 sertie 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 microblal activities provided by bacteria. At the final stage of this process (in the foïlowing 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 belteved 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 20 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 bitter 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*C, which, however, inevitably leads to a réduction of désirable healthy cocoa ingrédients.

[0007] WO 2014/130539 A1 discloses an alternative method of processing fruit seeds without the need of microblal fermentation, wherein the seeds are treated by adding unfermented seeds to a solution of a defined concentration of éthanol in a volume sufficient 30 to cover the seeds, and maintaining the solution at a set température for a certain period of time.

[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 grindlng the suspended beans or nibs, heating the suspension, and decanting the same such that said 35 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 fruits 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 cocoa fruit, such as e.g. polyphenols, antioxidants, vitamins and/or sugars, and also make idéal use of the sweetening properties, rich aromatic profile and nutritionally useful components of the cocoa pulp, has hitherto not been adequately addressed.

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

SUMMARY OF THE 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 explained in detail in the sedion below and further advantages will become apparent to the skilled artisan upon considération of the invention disclosure.

[0012] Generally speaking, in one asped the présent invention provides a method for processing cocoa fruits, comprising the steps of: adding water to cocoa beans to form a suspension; wet grinding said suspension; subjeding 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 minor 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; wherein the cocoa beans are non-depulped; or wherein cocoa pulp contained in cocoa fruits are separated from the cocoa beans In a depulping step, processed separately from the cocoa beans, and subsequently added to the suspension before or during any of steps (a), (b), (c), or (d).

[0013] A further aspect of the présent invention is the provision of a construction kit for chocolaté or chocolate-like 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-like products comprising the steps of: adding water to cocoa beans to form a suspension; wet grinding said suspension; subjeding 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 (iight 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 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; recombinlng the cocoa aroma extract with the cocoa butter extract; mixing the recombined extracts with said cocoa powder extract, said polyphenolic powder extract and/or milk powder; and conching said mixture; wherein the cocoa beans are nondepulped; or wherein cocoa pulp contained In cocoa fruits is separated from the cocoa beans In a depulplng step, processed separately from the cocoa beans, and subsequently added to the suspension before or during any of steps (a), (b), (c), or (d), or before or during steps <f), (g) and (h). ' ' [0015] A further aspect of the présent invention is a chocolaté or a chocolate-like product obtained by using the aforementioned methods or the aforementioned construction kit.

BRIEF DESCRIPTION OF THE 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 following method of manufacturing chocolaté according to the subject invention.

[0017] FIG. 2 schematically illustrâtes an exemplary treatment of the water phase upon 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 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. 4C schematically illustrâtes an exemplary method for preparing a chocolaté or chocolate-like product with 100% cocoa using the fractions obtained after séparation and processing of the fat, solid and water phases and cocoa pulp/mucllage as a natural sweetener.

DETAILED DESCRIPTION OF THE INVENTION [0022] For a more complété understanding of the présent Invention, reference is now made to the following description of the illustrative embodiments thereof:

Method for Processing Cocoa Fruits [0023] The method for processing cocoa fruits according to a first embodiment of the présent invention Is generally characterized by the steps of: (a) adding water to cocoa beans with or without cocoa pulp and mucilage to form a suspension; (b) wet grinding said suspension; 10 subject in g said suspension to a heat treatment at a température of 70*C 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 15 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 the cocoa beans are non-depulped; or wherein cocoa pulp contained In cocoa fruits are separated from the cocoa beans In a depulping step, processed separately from the cocoa beans, and subsequently added to the suspension before or during any of steps (a), (b), (c), or (d).

[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 solid phase) , respectively, Is achieved. The expression separating cocoa aroma and a polyphenolic powder from at least the water phase refers to operations by which cocoa aroma and 25 polyphenolic powder are retrieved 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] In the fruit pod of Thaobmma 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 30 and opened me ch an ically or manually, which Is preferably carried out in a sanîtary facility, the cocoa beans are separated from the shell of the cocoa fruit.

[0026] It Is to be noted that the expression cocoa pulp as used in the description of the présent Invention Is understood so as to encompass the mucilage contained In the cocoa pods. In analogy, the term non-depulped cocoa beans’ as used herein dénotés the 35 components of the cocoa fruit obtained by removing the shell from the cocoa pod, I.e. cocoa beans with pulp, mucilage, possibly with residual amounts of shell components.

[0027] Depending on the desired teste characteristics, the 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.

[0028] The depulping of the cocoa beans may be carried out manually or mechanically. In a 5 preferred embodiment, the cocoa pulp is separated from the beans by using a mechanical séparation device. In a further preferred embodiment, the cacao beans are separated from the pulp 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 sieved through the cylindrical sieve without causing damage to the 10 cocoa beans. An exemplary mechanical separator which may be used for this purpose is known from US 2013/0316056 Al. 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 reintroduced into the intermediate products and/or extracts during the further steps of the methods of the présent invention, which will be 15 explalned in further detail below.

[0029] In a preferred embodiment, the cocoa pulp obtained in the depulping step is processed separately from the 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 20 its relatively high sugar content. Advantageously, said approaches allow a maximum amount of the nutritlonally bénéficiai components of the cocoa pulp to be reintroduced 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 cocoa pulp to be reintroduced may be derived from the same cuitivar as the cocoa beans, which may be advantageous e.g. If the 25 extracts and/or the final cocoa product is intended to be a pure-origin product. Altematively, the pulp may be derived from a different cuitivar than the cocoa beans or be a blend of different cultivars.

[0030] In a preferred embodiment, the separate pre-processlng of the cocoa pulp and mucilage obtained In the depulping step may comprise mechanical and/or chemical 30 séparation and removal of undesired components. Such undesired components may comprise residual shell components and compounds contributing to an overiy bitter, acidic and/or unpalatable taste, for example. In a further preferred embodiment, the separate processing of the cocoa pulp and mucilage obtained In the depulping step comprises neutralizing and/or removing acidic components, such as e.g. citric acid and/or acetic acid. 35 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 5 used as a natural sweetener within the cocoa product.

[0031] In a preferred embodiment, the cocoa beans (either depulped or non-depulped) subjected to step (a) are unfermented.

[0032] The expression fermentation generally refera to any activity or process involving enzymatic or metabolic décomposition (digestion) of organic materials by microorganlsms, 10 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 term unfermented, as used herein, refera 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 Dirnick, Qualitative and Quantitative Measurements of Cacao 15 Bean Fermentation, In Proceedings of the Cacao Biotechnology Symposium, Ed. P. S.

Dirnick, p. 55-74, The Pennsylvania State University, 1986). In general, the fermentation Index of unfermented beans is less than 0.5.

[0033] In a further 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 20 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.

[0034] In particular, tt 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 25 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 30 effectively as possible.

[0035] 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.

[0036] In conventional cocoa bean processing methods, using an aqueous acidic medium as 35 Incubation medium may be disadvantageous in that substantial amounts of the acid used (usually inorganic or organic acids with preference for amphiphtlic acids, while acetic acid Is especially preferred since it has been shown to effectively penetrate the cocoa beans and pervade blological 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 neutralizatlon, distillation, extraction, emulslon-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-bitter or non-acidic taste may be achieved.

[0037] 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 represents a simple, reproducible and controllable alternative to microbial (i.e. yeast and bacterial) 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 viewpoint of germination inhibition effîciency and processing costs, the concentration of éthanol in the incubation medium is at least 2 vol.-% and less than 7 vol.-%. [0038] The incubation medium may further comprise enzymes known in the art for controlled enzyme-catalyzed reactions in order to facilitate formation of aroma precursors, such as hydrophilic oligopeptides and hydrophobie free amino acids, for example.

[0039] 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.

[0040] The Incubation step may further encompass one or more mechanical and/or physicai 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 physicai treatment may comprise an infra-red treatment and/or a vacuum treatment, for example.

[0041] In case the cocoa beans hâve been Incubated in accordance to any of the abovedefined 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. · [0042] In a preferred embodiment, the incubated beans are subjected to step (a) without an intermediate drying step. in a further preferred embodiment. the cocoa beans used for step (a) hâve not been predried at ail. These embodiments are especlally advantageous in terms of processing costs due to the lower energy expenditure. - . ·. : - - - [0043] As a starting material for step (a), whoie cocoa beans that may hâve been incubated may be used, or 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).-.

[0044] The subject cocoa fruit processing technique generally begins in step (a) with forming a suspension of cocoa beans by adding water, either prior or during the grinding of the cocoa beans/nibs.

[0045] 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, especially preferably about 3:1, which may advantageousiy affect the processability in the further steps (e.g. facilitated pumping, grinding and easier phase séparation).

[0046] If désirable from the viewpoint of introducing additional flavors, alternative watercontaining liquids 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 alone 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 falls 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 retained and may favorably Internet with the primary and secondary flavors of the cocoa bean.

[0047] In order to obtain coffee-flavored cocoa products, coffee beans (whoie or broken, unroasted or roasted) may be mixed to the 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.

[0048] In step (b), the 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 smaller, more preferably 40 pm or smaller, even more preferably 20 pm or smaller. 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 size réduction may be accomplished by using dise mills (e.g. perforated dise mill), coiloid mills (e.g. toothed colloid mills), 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 avaîlable 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 signifîcant frictional heat production or high mechanical forces îs avolded. 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 mllied suspension may be pumped to a toothed colloid mill for a fine grinding step.

[0049] 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 overail thermal load and prevent émulsification.

[0050] In 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 vlewpoint 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. In 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.

[0051] 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 major component and solids and/or water as minor components and said solid phase comprising cocoa powder and water. Preferably, devices empioying centrifugal forces may be utilized to achieve mechanical particle séparations, such as decantera 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 oil products may be separated from non-oil products.

[0052] Multiple phase séparation and recombination steps may be employed to achieve an 5 Improved séparation between the water phase (heavy phase), the fat phase (light phase) and the soiid 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 solid phases from the initial decanting step or at a later processing stage of said phases. Also, the 10 water phase may be subjected to further purification steps, e.g. by filtration using vacuum rotation fîlters in order to remove fine particles and reduce cloudiness of the liquid.

[0053] 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 15 at least the water phase, optionally also from the solid phase) and a polyphenolic concentrate (from the water phase), as is illustrated by Fig. 1.

[0054] 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 20 step) and residue water (which may be optionally added to the water phase prior to aroma recovery). Cocoa butter is obtained by fïltering the purified fat phase.

[0055] The (wet) solid phase obtained after séparation in the three phases may be optionally treated with a heatable roll grinder to reduce particle size and begin pre-drying. Also, sugar, sugar solution and/or fruit juices may optionally be added to separated cocoa solids before 25 drying to Improve fiavor development during the drying/roasting process.

[0056] 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 viewpoint of reducing the thermal ioad and preservlng the health-inducing components preferably at a température selected from between 55 and 70’C under reduced pressure, in order to allow 30 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.

[0057] The method of carrying out the drying/roasting is not particulariy limited and may e.g. be accomplished in a drum dryer.

[0058] In a preferred embodiment. the drying/roasting step is carried out in a mixing device as is disciosed 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 predetermined température. The tubular body has an Inlet and outlet openings for the solid phase. The outlet opening communlcates, by means of a du et, 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 simultaneously 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 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.

[0059] In the above-described cocoa bean/nib processing methods, addic components, such as e.g. acetic add 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 conveniently neutralized and/or removed by treating the water phase appropriately upon phase séparation.

[0060] The method of removîng free add via the water phase is not particularly limited and may be carried out by any suitable method known in the art. For example, acetic add 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, safting out or combinations thereof. Aftematively, acid may remain in the water phase if cocoa aroma and polyphenolic powder are selectively extracted therefrom. As is illustrated in Fig. 2, free add and other undesired water-soluble components, such as astringency-inducing and/or bitter low-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.

[0061] The neutralization and/or removal of free acid via the water phase has significant advantages over the methods disclosed In prior art, a few of which will be discussed in the following:

[0062] Acid is extracted from the cocoa beans or nibs 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, anti-oxldants, vitamins may be preserved. Also, theduration ofthe conching process maybe significantiy reduced.

[0063] Furthermore, since the relatively high costs Involved with the use of water and its removal are far outweighed by energy savîngs 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.

[0064] In addition, In contrast to conventional cocoa product manufacturing, cocoa beans having relatively high acid contents and/or being in varylng fermentation stages may be used to produce high-quality cocoa products, such as chocolaté.

· . [0065] A remarkable advantage of the présent Invention is that undesired hydrophîlic

- 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 10 bittemess 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.

[0066] It has further been found that the water phase obtained In the decanting step also contains desired flavors, which may be recovered by subjecting the water phase to a first 15 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).

[0067] In an optional second concentration phase, évaporation of excessive water may performed to obtain polyphenolic powder.

[0068] Removal of undesired water may be achieved using évaporation techniques which, when employed, can desirably, 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 carried out under low pressure (less than 300 mbar) and room température In order to minïmize the thermal load.

[0069] 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 préserve aromatic compounds). However, if both microorganism spoilage and 30 contamination occurs, heat treatment and deodorization may be employed. Advantageously, the method according to the présent invention allows a fast processing of the cocoa beans/nibs, so that growth of microorganisms may be kept at a minimum, however.

[0070] Using the herein described technique(s), cocoa beans may be efficiently processed to produce désirable, commercïally valuable yields of dried and extracted cocoa powder, cocoa 35 butter with hydrophobie cocoa flavor, hydrophilic cocoa flavor, and polyphenoi 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 least, high levels or sugar additions) when used in food stuffs. At the same time, the présent method makes idéal use of the sweetening propertles, rich aromatic profile and nutritionally useful components of the cocoa pulp contained ln the pod, whîle offering the possibility of fine-tunlng the acidic flavors according to the desired taste. Thus, the présent invention allows the manufacturing of cocoa products, wherein high levels of the nutritionally useful components naturally contained In the cocoa fruit hâve been preserved without compromlslng a pleasant taste, as will be further set out below.

Construction Kit for Chocolaté or Chocolate-Like Products [0071] ln 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 ln the first embodiment outllned above Is provided. ln 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. ln a preferred embodiment, the cocoa product construction kit according to the présent invention comprises ail of the abovementïoned extracts.

[0072] The term chocolate-like product, as used herein, refers to a product which falls into the legal définition of a chocolaté* of at least one country, but not ail countries, since it deviates ln the type and/or the content range of a component legally defining 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.

[0073] The construction kit for chocolaté and chocolate-like products according to the présent invention advantageously provides starting matériels for a large variety of hlghquality cocoa-based products, wherein water-soluble undesired hydrophilic components (such as bltter and/or astringent low molecular polyphenols (e.g. catechlns)) 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.

[0074] 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, variety and vintage of cocoa bean - especially the primary flavors thereof - are perceptible, without unpleasant acidity, astringency or bittemess.

[0075] 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 given hereinbelow.

Methods for Manufacturing Chocolaté or Chocolate-Like Products [0076] 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 variety of chocolaté products, as will be described in the following third embodiment.

[0077] 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 drying/roasting step (as indicated In Fig. 2) are first added to the cocoa butter. Before being subjected to a conching 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, mllk powder Is further added, preferably prior to the mixing step. Optionally, an emulsifying agent (e.g. lecithin) may be added prior to conching to reduce viscosity, control sugar crystalllzation 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.

[0078] The conching process redistributes into the fat phase the substances from the dry cocoa that croate flavor, while removing unwanted acetic, proptonic, and butyric acids from the chocolaté, reducing moisture, and meliowîng the flavor of the product. The température of the conche Is controlled and varies dependlng on the different types of chocolaté (from around 49 ’C for milk chocolaté to up to 82 'C for dark chocolaté). While being to some degree dépendent on the température, the conching 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 less. Thus, a loss of désirable aroma characteristics as observed at long conching times does not occur. [0079] As alternative chocolaté product that may be manufactured by the method of producing chocolaté according to the présent invention as indicated in Fig. 4B, white chocolaté may be mentioned, which Is usually a blend of cocoa butter, sugar, milk solids, emulsifier (e.g. lecithin), as well as optionally vanilla for flavor, depending on the produceris reclpe. 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.

[0080] Conventional methods for the production of white chocolaté invoive the use of deodorized cocoa butter. Specifîcally, cocoa butter is conventionally prepared by methods comprising the alkalization of cocoa liquor, which cont ri butes 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 provide a low-odor, non-bitter 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 vitamins and anti-oxidants in the cocoa butter.

[0081] 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-oxidants.

[0082] In addition, by recombining 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.

[0083] A process of manufacturing a chocolaté or chocolate-like product having a cocoa content of 100% is schematically described in Fig. 4C. The scheme baslcally 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 bittemess commonly assocîated with 100% cocoa products is avoided and wherein at the same time favorably high amounts of nutritionally bénéficiai and valuable components of the cocoa fruit, such as e.g. polyphenols, antioxidants, vitamins are contained. Last but not least. the final product also makes use of cocoa pulp and comprises valuable nutritlonal and health-induclng 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 preprocessing of the pulp or via removal of acidic components through the water phase.

[0084] 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 filiing, 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.

[0085] Once given the above disclosure, many other features, modifications, and improvements will become apparent to the skilled artisan.

Claims

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

(a) adding water to 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 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 ¹ '__ (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 the cocoa beans are non-depulped; or wherein cocoa pulp contained In cocoa fruits are separated from the cocoa beans In a depulping step, processed separately from the cocoa beans, and subsequently added to the suspension before or during any of steps (a), (b), (c), or (d).

2. The method according to claim 1, wherein the cocoa beans are non-depulped and are subjected to step (a) Immediately after opening of the cocoa fruit and separating the nondepulped cocoa beans from the shell.

3. The method according to claim 1, wherein the processing of the cocoa pulp comprises neutralizing and/or removing acidic components, the acidic components being preferably citric acid and/or acetic acid.

4. The method according to any of the preceding claims, wherein the cocoa beans are nondepulped; or wherein cocoa pulp contained In cocoa fruits are separated from the cocoa beans In a depulplng step, processed separately from the cocoa beans, and subsequently added to the suspension before step (c).

5. The method according to any of the preceding claims, wherein the cocoa beans in step (a) are unfermented.

«

6. The method according to any of the preceding claims, wherein said cocoa beans hâve been subjected to an Incubation step prior to step (a).

7. The method according to claim 6, wherein sad cocoa beans are non-depulped.

8. The method according to any of claims 6 and 7, wherein the Incubation step comprises adding cocoa beans to an ethanolic solution at a température of between 10’C and 70“C for a period of between 2 hours and 10 days, the volume of the ethanolic solution being sufficient to cover the cocoa beans.

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

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

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

12. A method for producing chocolaté or chocolate-like products comprising the steps of;

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

(b) wet grinding said suspension;

(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 milk powder; and (h) conching said mixture;

wherein the cocoa beans are non-depulped; or wherein cocoa pulp contaîned in cocoa fruits is separated from the cocoa beans In a depulping step, processed separately from the cocoa beans, and subsequently added to the suspension before or during any of steps (a), (b), (c), or (d), or before or during steps (f), (g) and (h).

13. The method according to claim 12, wherein the processing of the cocoa pulp comprises neutralizing and/or removing acidic components, the acidic components being preferably citric acid and/or acetic acid.

10

14. The method according to claim 13, wherein the acidic components are citric acid and/or acetic acid. ' ·

15. A chocolaté or chocoiate-like product obtained by the method according to any one of daims 12 to 14. - -- ·