RU2129804C1 - Praline confectionery production method - Google Patents

Abstract

FIELD: confectionery industry. SUBSTANCE: method involves preparing recipe mixture containing sugar powder, dry cocoa, coconut oil, ground cashew nut with particle size of 0.5-3.0 mm and temperature of 50-55 C, and dry milk; mixing mentioned components in mixing machine; adding a portion of fat in the form of cacao-butter used in an amount of 36-41% of the total amount of butter and heated to temperature of 38-43 C. Recipe mixture is ground in five-roller mill till grinding extend of mass reaches 89-95%. Method further involves kneading obtained mass by mixing ground powder mass in mixing machine with remaining portion of fat in plasticized state, which is heated to temperature of 16-21 C. Such procedure at the fist stage provides uniform distribution of components, when fat is used in an amount reduced by twice, due to increased temperature of ground nut, melted fat and increased time of operation. Increased grinding extent (89-95%) is due to limiting the capacity of five-roller mill to required value. Whipped praline mass is obtained at kneading stage by using plasticized fat heated to temperature of 16-21 C at which fat crystalline structure is kept and, as a result, praline-based product cooling process is intensified upon molding process. EFFECT: increased efficiency, improved gustatory quality of confectionery products and simplified method. 3 cl, 2 ex

Description

 The invention relates to confectionery production, namely the production of confectionery products on a praline basis (sweets, cakes and waffle products).

 Praline masses and praline masses are a finely divided mixture of fried grated oily nut kernels or oleaginous, cereal and bean seeds with sugar and solid fats. To improve the taste and nutritional properties, dry milk products (milk powder, cream), skim milk, cocoa products (grated cocoa and powder), honey and other components of the formulation are introduced into praline masses.

 Solid fats are used as solid fat, the main builder: cocoa butter, cocoa butter equivalents, cocoa butter substitutes and confectionery fat. Liquid fats of nuts give plasticity to pralin masses. The presence of solid and liquid fats in a praline mass determines its strength properties and viscosity. In the production of praline masses, the kernel of nuts is used: almonds, peanuts, cashews, hazelnuts (hazelnuts, hazelnuts).

 Praline masses are very similar to chocolate mass in composition, production method and some physicochemical properties. Praline masses, like chocolate ones, contain about one third of fat and sugar, about 50-60%.

 An analysis of the technology and production techniques of praline products at confectionery enterprises showed that their preparation is carried out mainly in a batch manner. Mechanized production lines were created only from the stage of molding praline masses.

The production of these groups of products is carried out according to the following flow chart:
1. Mixing prescription components (preparation of the prescription mixture) with a portion of the solid fat.

 2. Rolling (grinding) of the recipe mixture on five-roll mills.

 3. Warm up (mixing) the crushed praline masses with the rest of the fat.

 4. The formation of praline masses by extrusion or spreading in a mechanized way.

 5. Cooling molded praline-based confectionery.

 The following methods are known for preparing praline masses.

According to the first method, at the first stage, all prescription components are mixed with 2/3 parts of fat, which is 65-70% of its total amount. After roasting, grind the nuts to a ointment-like consistency to increase the palatability of the praline masses, as the release of vegetable fats gives the masses a specific taste. In order to avoid dilution of the mixture due to the high fat content, the mixing time is not more than 5-10 minutes at a temperature of 24-25 ^o C.

 During the mixing process, fat envelops solid particles (powder, milk powder, cocoa powder). In accordance with the law of colloid chemistry, the boundary layer of fat acquires the properties of a solid and helps to increase the release properties. Thus, on the one hand, fat affects the plasticity of the mass in the process of its production, and on the other hand, it provides strength of products during crystallization during cooling.

 The resulting recipe mixture is a coarse-grained system, so in the next stage it is subjected to grinding in five-roll mills.

 Short-term kneading (5-10 minutes) at the first stage does not ensure the achievement of a high final uniformity of the praline mass, but it contributes to a sharp increase in the productivity of five-roll mills to 1000-2000 kg / h, while at the same time significantly reducing the grinding quality.

 According to the second method, the mixing of all prescription components is carried out with the minimum possible amount of introduced fat of the order of (18-22%), for 13-15 minutes under conditions of relatively low intensity of mechanical stresses (kneading organs rotational speed of not more than 50 rpm). The short duration of the mixing of the components and the small amount of introduced fat do not ensure the uniformity of their distribution in the recipe mixture. The increased viscosity of the mixture of about 780-900 Pa • s also makes it possible to increase the productivity of five-roll mills to 1000-2000 kg / h, i.e. 2.5-5 times exceed their passport performance. Due to the uneven mixing at the first technological stage, the recipe mixture after rolling (grinding at the second stage) has an uneven local structure: sometimes dry, then very oily. In places of greater accumulation of fat, aggregates of solid particles are created, as a result of which a film with a relatively large thickness is formed. During rolling, the film prevents the particles from moving inside the unit under the influence of mill rolls, since its adhesive properties are much smaller than those of solid particles. The aggregates seem to slide relative to the rotating rolls of the mill and the dispersion of solid particles deteriorates sharply. In the same places in the prescription mixture, where solid particles predominate, the formation of the same aggregates occurs under the influence of molecular cohesive forces. The crushed mass is obtained, although it has a powdery consistency, but it is coarsely dispersed with large impregnations tangible in the tongue.

 It should be noted that the stage of rolling (grinding) of the recipe mixture is fundamental to the way of obtaining finished products of high quality.

 In the process of rolling (grinding) correctly prepared homogeneous recipe mixture, there is a decrease in the size of the particles of the solid phase by crushing them. As a result, the total surface of solid particles increases. At the same time, the amount of fat in the mass before rolling becomes insufficient to bind the particles into a uniform plastic mass. This leads to the fact that the existing fat is no longer able to completely cover each particle of the solid phase. There is a kind of "drying" of the prescription mixture and from a plastic state it passes into a powder. The main technological indicators characterizing the process of rolling (grinding) pralin masses on five-roll mills is the degree of its grinding in percent (according to Reutov), effective viscosity of the mass, temperature before and after rolling, and productivity of the five-roll mill.

 As already noted, the degree of grinding of praline masses should be close to chocolate. The degree of grinding during rolling of praline masses or the number of particles up to 25 microns in size (the border when a person’s tongue begins to feel large particles) largely depends on the gap between the rolls of the five-mill mill, i.e. from her performance. With a five-mill mill productivity from 2000 to 3000 kg / h, the degree of grinding of praline masses is 75-60%, at 1000-1800 kg / h - 80-76%, at 750-900 kg / h - 85-82%, at 600- 500 kg / h - 89-90% and at 400 kg / h - 89-95% according to Reutov.

 After rolling (grinding) at the final stage, the praline mass is subjected to a warm-up. The process of warming up praline masses is one of the main operations that determine the subsequent modes of molding and structure formation during cooling. The main purpose of the warm-up is to obtain praline masses of a homogeneous structure, plastic consistency and with careful mutual distribution of prescription components (especially its fat phase) in the entire volume.

 At the stage of the warm-up to ensure the process of forming praline masses, the powdered rolled mass is again brought into a plastic state. This is achieved by mixing the crushed mass with the remaining amount of fat in the recipe.

In the industry using existing technologies, the stage of curing is carried out in different ways. In the first case, after cooling the crushed praline recipe mixture to a temperature of 24-25 ^o C (workshop temperature), the mass is fed to the warm-up with the remaining amount of fat in a crystallized state and mixing is carried out at temperatures of 26-28 ^o C, i.e. below the melting temperature of a mixture of fats in the mass. Under these conditions, with the usual short-term mixing (up to 10 minutes), it is not possible to obtain a mass of a homogeneous structure and, most importantly, to carefully distribute the crystallized fat phase. This affects the quality of the praline masses, contributes to the appearance of cracks in the molded products and leads to the need to increase the duration of their structure formation (i.e., the lines work with downtime).

According to other technologies, the crushed praline mass with a temperature of 35-40 ^o C is immediately crushed with the remaining part of the fat in the molten state. Under these conditions, when the masses are mixed for 20 minutes, a more uniform distribution of the fat phase occurs and a greater uniformity of structure is achieved.

However, this method, due to the liquid-like consistency of the mass, requires long-term cooling in large containers in the workshop for 12-24 hours to a molding temperature of 28-34 ^o C. This, as in the first case, creates conditions for the uneven flow of the process of crystallization of fats throughout volume of mass. The mass structure becomes coarsely dispersed and the process of structure formation requires very intensive cooling of the products after molding in a cooling cabinet (at a temperature of from -3 to +3 ^o C).

The main disadvantages of existing technologies include:
1. Obtaining an insufficiently homogeneous recipe mixture and a low degree of grinding after rolling.

 2. A long production cycle, which is 24-30 hours, which is mainly due to the need for long-term cooling of the crushed prefabricated praline before curing (mixing) or after curing the mass in preparation for molding.

 3. The homogeneity of the structure is not achieved at the stage of the warm-up, since mixing is performed for a short time (5-10 minutes), not intensively enough and at temperatures below the melting temperature of the mixture of fats included in the mass of pralines.

4. Molding is carried out at temperatures of 28-34 ^o C, significantly higher than the pour point of the mixture of fats included in the praline mass, which increases the duration of the process of structure formation of bundles in cooling cabinets and often leads to downtime molding equipment.

 Meanwhile, at the present stage, the confectionery industry is tasked with significantly improving the quality of confectionery products while optimizing the process.

 In this case, it is required to provide the maximum technological effect at the lowest cost. Scientific and technological progress in the production of praline masses is based on the use of modern developments in the field of physical chemistry of highly concentrated dispersed systems, the knowledge of which allows one to control the structural and mechanical properties of praline masses at all stages of their production in order to obtain finished products with predetermined properties and structure.

 In accordance with modern concepts of physical and chemical mechanics, praline masses belong to mixed coagulation-crystallization systems. At temperatures above the melting point of a mixture of fats, praline masses possess all the properties of coagulation systems. When products with praline masses are cooled in the process of structure formation, coagulation disappears and pronounced crystallization properties are manifested. This is explained by the presence of fat-containing fractions in pralin masses that are prone to crystal formation.

 The closest in technical essence and the achieved result to the proposed proposal is the method of production of praline masses described in the book "Sweets" (M., Food Industry, 1979, since 191).

 According to this method, the curing is carried out at temperatures of 35-40 in the conditions of intensive mixing of the masses until the destruction of their structure. The mass is obtained with a viscosity of 40-50 Pa • s with a velocity gradient of 10 s. Such warm-up conditions ensure uniform distribution in the mass of the mixture of fats in the molten state.

 The process of warming up the praline masses continues until the structure is completely destroyed and a high degree of homogeneity of the distribution of the fat fraction is achieved (the praline mass turns out to be a greasy consistency) is characterized by stabilization of rheological characteristics, viscous and strength properties. The duration of the warm-up (mixing) during which the mass acquires stable rheological properties is: for melanger about 25 minutes; for a mix machine with a capacity of 150 and 250 kg and a rotation speed of Z-shaped blades of the order of 40 rpm - 40 minutes, and with a rotation speed of up to 60 rpm - 35 minutes and above 80 rpm - up to 20-25 minutes.

The praline mass is cooled before molding in a thin layer in a three-roll mill with brine as a refrigerant. The mass retains a plastic consistency. The temperature of the chilled mass is 4-5 ^o C higher than the pour point of the mixture of fats included in its composition. The temperature of the brine is minus 6-8 ^o C. The method of preparation of praline masses was developed by the Research Institute of the Confectionery Industry in 1975-1978.

 Despite the achievement of high palatability of the mass, elimination of equipment downtime and reduction of the amount of returnable waste at the cutting stage, this method requires additional equipment (a three-roll mill with brine), large production areas, increases energy consumption and does not provide the ability to control the process at the stage of warming and cooling -for the short duration of the impact of the mass during the passage of the three-roll mill (only 2 points of exposure) and the inability to stabilize the quality idents indicators mass before molding, which leads to disruption of constant thickness articles after molding.

 The technical result of the invention.

 The ability to control the processes of obtaining the final structure of products on a praline basis at all stages of production, the intensification and stabilization of the process, improving the taste of the masses, increasing the accuracy of dosing at the stage of forming confectionery.

The technical result is achieved by the fact that before rolling into the recipe components fat is added in an amount of 36-41% of the total amount in a liquid-like state with a temperature of 38-43 ^o C (i.e. 4-6 ^o C above the melting temperature of the fat) and mixing lead for 30-35 minutes, and at the stage of warming up the fat is introduced in a plasticized state.

 To prevent the release of vegetable fat from the cells of nuts, nuts are fed into the mixing machine in a crushed form, in contrast to the generally accepted method, when the nuts are abraded to a liquid-like consistency. (N.V. Karusheva "Technology of sweets and toffee", M. Food industry, 1976, p. 64-67).

After heat treatment, the nuts are fed for cooling to a temperature of 55-65 ^o C (according to existing technologies, cooled to 35-40 ^o C) and the husk is sifted. Grinding into grains (to obtain particles with a size of 0.5-3 mm) is carried out on a top (such as a meat grinder), with a mesh cell diameter of about 6 mm.

Nuts after the top with a temperature of 50-55 ^o C in the form of a coarse-grained mass is served in a kneading machine. At a relatively high temperature of nuts, much less effort is required to force the mass during transportation through the top of the top. It also prevents the release of vegetable oil from walnut cells. Fat is served in a liquid state in the amount of 36-41% of the prescription with a temperature of 38-43 ^o C.

 The reduction of fat at the stage of preparation of the recipe mixture to 36-41% (according to the existing technology of the prototype 45-50%) and the increase in viscosity of the system as a result of this ensures the relative movement of particles in the mass under the action of kneading organs. This is explained by the fact that under conditions of increased viscosity, solid particles slip to a lesser extent relative to each other and, under the action of kneading organs, begin to fray, contributing to the destruction of aggregates from particles and the release of fat contained in aggregates. It also provides improved conditions for uniform distribution of components in the recipe mixture.

 The rotational speed of the kneading organs is more than 80 rpm, the increased duration of mixing the components up to 30-35 minutes and the increased viscosity of the system at the very beginning of the process helps to obtain a homogeneous structure of the recipe mixture and envelop the maximum amount of solid particles with fat.

The proposed methods ensure the achievement of the required viscosity of the recipe mixture before grinding it on a five-roll mill. A great influence on the processes of preparation of praline masses is exerted by the temperature from the chopped semi-finished product and the introduced part of the fat. According to the proposed method, the temperature of the recipe mixture at the end of preparation is 3-5 ^o C higher than the melting temperature of the mixture of fats (almost 38-43 ^o C). This ensures the viscosity of the recipe mixture before rolling in the range of 170-250 Pa • s (with a velocity gradient of the order of 10 s), which also positively affects the limitation of the productivity of the five-roll mill to 550 kg / h.

 The above technological methods provide a homogeneous powdery finely divided praline mass with constant sizes of crushed particles. The productivity of the five-mill mill is limited to 450-550 kg / h, this ensures the degree of grinding of the mass - 89-95% (according to Reutov).

A fundamentally new way is proposed to carry out the stage of warming up, instead of a two-stage warming up using the existing prototype technology (first, the warming up process is carried out in a Z-shaped mixing machine with molten fat at a temperature of 35-40 ^o C, followed by cooling in a three-roll mill to a temperature of 3-5 ^o C above the pour point of the mixture of fats). In this invention, we propose a warm-up process in one step, by mixing the powder mass in a mixing machine with the remaining amount of fat (59-64%), which is in a plasticized state with a temperature of 16-21 ^o C.

 The stage of the warm-up is carried out at room temperature (in contrast to existing methods) - without supplying the coolant to the shirt of the kneading machine. Fat mastication is carried out either in mixing machines or in special plasticizers used in the dairy industry, with a rotational speed of the kneading organs of the Z-shaped kneading machine upon receipt of a praline mass of the order of 80-100 rpm. Along with the uniform distribution of mass and fat, there is also a partial capture of air. The density of the mass prepared on plasticized fat after warming up is 680-1050 kg / m (with existing technologies, the mass density is 1050-1280 kg / m).

The duration of the warm-up phase depends on subsequent technological operations. In the case of molding praline masses by pressing out to form bundles, the viscosity of the mass should be in the range of 150-230 Pa • s, while maintaining ductility. This is ensured by knocking down the praline mass for 13-18 minutes at a rotational speed of the kneading organs of at least 80-100 rpm. The temperature of the mass at the end of the process before molding should be in the range of 21-24 ^o C.

When applying praline filling on wafer sheets by contact method or by extrusion on three-roll spreading machines, the mass should have a viscosity of about 100-150 Pa • s. This is achieved by increasing the duration of the knocking stage to 25-30 minutes and the temperature of the mass 25-28 ^o C during the warm-up process. The mass after the warm-up has a more magnificent consistency, the filling layer is applied 1.3-1.4 times more on the wafer sheet. This improves the accuracy of dosing, especially when using a contact type spreading machine. It became possible to more accurately withstand the ratio of sheets and toppings and, thereby, dramatically improve the taste of wafer products.

When preparing pralines in a new way using plasticized fat, there is no need to use expensive three-roll mills and there is no need for brine to cool it, production areas are saved and line layout is simplified. The advantages of the proposed method include reducing the cooling time of products after molding - within 8-10 minutes at a temperature in the cooling cabinet of about 8-10 ^o C (in existing production lines, the temperature in the cooling cabinets is not higher than 3 ^o C). This is due to the fact that most of the fat - up to 70% is involved in the preparation of praline masses in a crystallization state. The intensification of the process consists in eliminating the stage of formation of crystallization centers, since the crystallization structure of fat is not broken. This allows the production lines to work in a continuous flow, without stopping the lines. Thus, it is provided;
- in the production of praline sweets - improving the quality of cutting bundles on the hull, reducing return waste at the stage of transverse cutting by 1.5-2%; increase productivity of molding equipment up to 30% by eliminating downtime and significantly improve the surfaces of molded harnesses and the constancy of the geometric dimensions of the bodies;
- in the manufacture of waffle products - a significant increase in their taste due to an increase in the thickness of the filling layer and, in this regard, the predominance of the filling taste over the sheet; increased line productivity due to the organization of the lines without downtime; cutting layers into individual products immediately after the cooling stage due to the achievement of the necessary plastic strength (10.0-15.0 • 10 Pa).

 In both cases, space is saved and production efficiency is increased.

As an example of the performance of the proposed method
1. Upon receipt of candy praline masses.

To prepare the recipe mix, take powdered sugar 170.62 kg, cocoa powder 75.22 kg, coconut oil 24.95 kg, crushed cashew nuts (with a particle size of 1.0-2.5 mm) 17.95 kg, milk powder 16.73 kg and add 32.82 kg of cocoa butter, that is 40% of the total oil. The components are mixed in a mixer for 25 minutes instead of 10 minutes using existing technology. This achieves the required viscosity of 230 Pa • s, the temperature of the prescription mixture 25 ^o C.

 The recipe mixture is subjected to grinding on a five-roll mill with a productivity of 400 kg / h, while the degree of grinding of the obtained powder mass is 95%.

The warm-up process is carried out by mixing the pulverized powdered mass in a mixing machine with fat. 355.74 kg of ground mass and 53.74 kg of cocoa butter in a plasticized state are fed per load. The mass is stirred for 20 minutes to obtain a plastic mass with a viscosity of 180 Pa • s at 21 ^o C.

 2. Upon receipt of the praline wafer filling.

 A praline mass is prepared by mixing the recipe components with part of the fat, rolling the mixture, then mixing the components with the remaining amount of fat at the stage of warming, cooling and molding.

Preparation of praline fillings is as follows:
At the station for preparing the recipe, in a Z-shaped mixing machine with a speed of 82 rpm, 5.50 kg of Konfao fat with a temperature of 38 ^° C, 4.75 kg of cocoa powder and 13.82 kg crushed roasted walnuts (geometric particle sizes 2.5-3.5 mm). After that, 23.20 kg of powdered sugar and 0.002 kg of vanilla powder, 6.37 kg of powdered milk, 1.67 kg of wafer sheet crumbs and 7.55 kg of returnable waste (scraps) are added. The total mixing time is 30 minutes. The viscosity of the obtained recipe mixture 190 PA • s.

 The resulting mass in the form of agglomerates of a dark color, a homogeneous consistency, a clay-like, somewhat clumped, is passed through a five-roll mill. The passage time of the mass through the five-roll mill is 8.5 minutes, which corresponds to a total mill productivity of 430 kg / h. The degree of grinding powder mass 91%.

 After passing through a five-roll mill, the mass is light, uniform, finely divided, powdery, light, with a delicate melting taste.

 Next, the mass passed through a five-roll mill is mixed with 9.29 kg of Frying fat in a TM-63 machine with Z-shaped blades and a blade speed of 82 rpm, with the heating of the kneading chamber switched off. Fat "Frying" is pre-plasticized. Mixing was carried out for 30 minutes.

 The viscosity of the filling before molding 110 PA • s.

The temperature of the filling is 22 ^o C.

 The finished filling is dark in color, whipped, of a uniform consistency, with a delicate melting taste. No particles were felt on the tongue.

 The density of the finished filling is 1028 kg / m, for comparison, the density of the filling prepared by the existing method is 1280 kg / m.

Claims (3)

1. A method for the production of praline-based confectionery products, comprising mixing the recipe components with part of the fat, rolling the mixture, kneading with the remaining part of the fat, molding by pressing or spreading and cooling, characterized in that when mixing the recipe components, the nut is crushed, with particles 0 , 5 - 3 mm and a temperature of 50 - 55 ^o C, the fat is served in a liquid-like state in the amount of 36 - 41% of the prescription with a temperature of 38 - 43 ^o C, during the rolling process, the degree of grinding of the mass should be in the range 89 - 95%, and from mink is carried out with the remaining amount of fat in a plasticized state with a temperature of 16 - 21 ^o C.  2. The method according to claim 1, characterized in that the mixing of the prescription components is carried out for 30 to 35 minutes at a rotation frequency of Z-shaped kneading organs of at least 80 rpm.  3. The method according to claim 1, characterized in that the recipe mixture before rolling should have a viscosity of from 170 to 250 Pa • s.