WO2019078750A1

WO2019078750A1 - Process for producing a carob bar

Info

Publication number: WO2019078750A1
Application number: PCT/PT2018/050040
Authority: WO
Inventors: Maria Margarida CORTEZ VIEIRA; Vera Lúcia DA CONCEIÇÃO DUARTE ALVES; Tânia Isabel DA PALMA MATEUS
Original assignee: Carob World Portugal, Lda.
Priority date: 2017-10-16
Filing date: 2018-10-16
Publication date: 2019-04-25
Also published as: PT110353A

Abstract

The present invention relates to an 8-step process for producing carob bars and to four recipes for carob bars produced by this process.

Description

DESCRIPTION

"ALFARROBA BAR MANUFACTURING PROCESS"

SCOPE OF THE INVENTION

The present invention relates to a carob tree bar process comprising 8 steps as well as 4 carob bar slices produced respectively with 9 or 7 ingredients and by the said process.

Carob

The carob tree (Ceratonia siliqua L.) is a tree belonging to the Leguminosae Family, essentially cultivated in the Mediterranean region, mainly Spain, Italy, Portugal and Morocco.

Locust bean seeds and pods are used as feedstock in industries such as food, pharmaceutical and cosmetic products.

Locust gum (LBG) is used as a natural food thickener, a stabilizer and flavoring agent, which can normally be added to a variety of products, such as ice-cream and candy (Durazzo et al., 2014; Seczyk et al. 2016).

Carob has long been used as a raw material for the production of food additives.

Due to its sweetness and taste similar to chocolate, as well as its low price, carob meal is widely used in the Mediterranean region as a substitute for cocoa in the food industry (Durazzo, et al., 2014; Seczyk et al., 2016).

The fact that the carob does not contain caffeine is a major advantage over cocoa.

Carob is characterized by a high content of soluble sugars (about 40-50%, mainly sucrose), low protein content (3-4%) and lipids (0.4-0.8%) and high content of polyphenols, especially tannins (Seczyk et al., 2016).

Polyphenols have good biological properties, such as antioxidant activity.

The antioxidant activity present in the polyphenols allows to prevent against the oxidation of some biomolecules, such as DNA, proteins and lipids (Seczyk et al., 2016).

Carob meal is a product that contains a high content of dietary fiber, minerals (Fe, Ca, Na, K and P) and vitamins (E, D, C, niacin, folic acid and B6).

Given the high nutritional value, there is an increased use of locust bean meal as a functional ingredient (Seczyk et al., 2016).

Due to the qualities of the carob, the products made from this raw material have a distinctive and unique quality in order to be able to assert themselves in the market without having to a substitute and / or substitute raw material for cocoa.

Carob Bar Development

Locust carob production process was carefully developed according to four carob rod recipes that were previously elaborated and selected through sensorial analysis performed through a panel of tasters.

The result of the four recipes, produced according to the carob rod manufacturing process described in the present invention, is presented as a natural and organic nutritional product which is manufactured from the processing of natural products with low sugar content , without cocoa and their respective endogenous exciting.

Within the aforementioned 4 recipes, 2 do not have the addition of milk, causing them to be considered vegan.

In a first stage of the elaboration of each one of the 4 bars, after identifying the necessary ingredients, it began by testing different bar recipes.

For this, some recipes were produced that served as a basis for the perception of the ingredients and quantities to be used in the bar, such as carob, fat, almond, milk, maltodextrin and sweetener.

The tests carried out showed that Almond left the soft bar, so we chose to put almond into pieces.

It was further found that the ingredients required milling for at least 2 hours in a ball mill to produce each of the 4 bars having a creamier texture.

After preliminary tests the mixing design was carried out in order to determine the optimal concentrations of the ingredients for the production of the following 4 recipes:

- bar of carob with milk and without almonds;

- bar of carob without milk and without almonds;

- bar of carob with milk and with almonds; and

- bar of carob without milk and with almonds.

In order to perform the mixing design, in the first sensory analysis the test panel consisted of 24 testers, 9 of whom were male and 15 were female.

The second sensory analysis was carried out by a panel of tasters consisting of 30 tasters, of whom 10 were male and 20 were female.

The third sensory analysis was performed on a panel of tasters consisting of 25 tasters, of whom 6 were male and 19 were female.

Average of the answers obtained in each characteristic. The characteristics of the 4 carob bars are selected by the 25 tasters according to the following 10 characteristics:

- brightness;

- color;

- aroma;

- hardness when cracking;

- fusion in the mouth;

- sweetness;

- bitterness;

- creaminess;

- flavor; and

- residual taste.

A number of tests were also carried out to define the substitute fats of cocoa butter and to adjust the appropriate amounts to the product.

We have also studied the fundamental processes in the development of the bar, namely the milling and tempering process that allow to obtain characteristic brightness, texture and appearance.

To further diversify the products, we also studied the addition of almond to the bars with and without milk, which is a typical fruit from the Algarve (Portugal), which will also value the carob tree.

The study of the shelf life of the bar during 4 months allowed to be estimated by different tests (storage at controlled temperatures of 20 ° C and 30 ° C with cycles of 12h until the appearance of fat bloom) that the four bar recipes described in the present invention may have a shelf life of 12 months.

The tables with the nutritional values and the special indications to be included in the label for the marketing purposes of the 4 products developed were elaborated.

The technical sheets of the ingredients or raw materials and the 4 products developed were also made.

Suppliers of alternative raw materials, namely fats and all the ingredients used, were investigated.

The costs of the raw materials for the production of the developed products were analyzed.

BRIEF DESCRIPTION OF THE PRESENT FIGURE

The following description is made with reference to the drawing which is presented for reference only, without any limiting character, and in which:

Fig. 1 - Flowchart of the carob rod manufacturing process

SUMMARY OF THE INVENTION

The carob rod manufacturing process and respective carob rod recipes are manufactured according to the process described in the present invention which is shown in Figure 1.

The 4 bar recipes that unique sensory, physicochemical and nutritional characteristics and were developed according to 10 characteristics, gave rise to the carob rod manufacturing process and respective carob rod recipes described in the present invention.

In addition to the judicious choice of 8 to 11 ingredients or raw materials that make up the respective recipes of the four bars, in the process of carob bar production, all equipment, temperatures, times and humidities of each of the 6 steps were also selectively selected so that each of the four bar recipes has unique sensory, physico-chemical and nutritional characteristics.

Process of carob bar production

The carob rod manufacturing process sequentially comprises the following 9 steps:

I ^to step - weighing of raw materials;

Step 2 - mixing the raw materials;

3 step - grinding of raw materials;

4 ^the step - conching the mixture;

Step 5 - hardening the mixture;

Step 6 - shaping the product;

Step 7 - cooling the carob bar;

8 step - stripping carob bar; and

Step 9 - packaging and storage.

In step I are weighed each of about 8-11 ingredients or raw materials that constitute each of the respective four recipes carob bars. In the second step will take place the mixture of vegetable fats in the following amounts:

33.30-43.85% palm vegetable fat; and

1.20-5.00% coconut fat.

Simultaneously in the said second step, it will also occur to the premix powder of the following quantities:

10.00-35.00% carob; and

0.01-0.04% sweetener;

30, 65-45, 60% maltodextrin-like dietary fiber; 0.00-20.25% skim milk powder;

0.18-0.50% emulsifier;

0.26-0.50% soy lecithin; and

0.00-15.00% pieces of toasted almonds with skin.

These aforementioned powders and fats are mixed in the mill during the third step.

In the third step will occur grinding of raw materials, for 2 to 12 hours at a temperature between 30 to 70 ° C and a particle size to be obtained of the ingredients with a particle size of from 10 to 30 m.

In the fourth step, there is the conching the mixture of fat and powders obtained in the previous step, for 6 to 24 hours at a temperature between 30 to 70 ° C to obtain the desired flavor, ensuring that the product when consumed are percecionado as homogeneous and has good rheological properties.

Then in the 5th, hardening of the mixture is performed by means of a temperadora for 1 to 4 hours and at a temperature between 25 and 50 ° C.

The quenching process of the base product in palm oil and locust beans significantly affects its physical and sensory properties of the blend.

The process was studied and fine tuned to control the temperature, crystallization time and stirring speed.

The temperature of the quench varies for each type of recipe to be produced, with milk and without milk, and respectively varies between 25 and 50 ° C.

In ^the step 6 is carried out at the molding mass through a die which will give the shape of the carob bar.

After molding, in step 7, ^the molds are cooled in a cooling tunnel for 0.2 to 1 hour, at a temperature between 5 to 18 ° C and a relative humidity of 30 to 60% relative humidity.

In the penultimate stage - the eighth step - will be held demoulding carob bar.

In step 9, and lastly, the packaging and storage will be performed.

The bar packaging process plays a key role in the preservation and protection of food during transportation and distribution. The packaging is effected in a flow pack that surrounds the bar with a BOPP film.

Then, in a cartoner, which places the bar in a carton, which allows to maintain the organoleptic properties, nutritional characteristics and prolong its life time.

These processes and methods of production and packaging have been studied and allow the best efficiency, product tuning and its conservation.

Carob bar

Locust bean bar is manufactured in accordance with the locust bean bar manufacturing process previously described.

At the level of the ingredients or raw materials the locust bean bar described in the present invention comprises the following ingredients:

33.30-43.85% palm vegetable fat;

1.20-5.00% coconut fat;

10.00-35.00% carob;

0.01-0.04% sweetener;

30.65-45.60% maltodextrin dietary fiber;

0.00-20.25% skim milk powder;

0.18-0.50% emulsifier;

0.26-0.50% soy lecithin; and

0.00-15.00% pieces of toasted almonds with skin.

Preferred embodiments of the present invention

Preferred embodiments of the present invention invention are related to the ingredients or raw materials used in each of the respective 4 carob rod recipes:

- bar of carob with milk and with almonds;

- bar of carob without milk and without almonds;

- bar of carob with milk and without almonds; and

- bar of carob without milk and with almonds.

The carob tree bar consists of 9 to 7 ingredients:

- 33.30-43.85% of vegetable shortening of palm;

- 1.20-5.00% coconut fat;

- 10.00-35.00% carob;

- 0.01-0.04% sweetener;

- 30, 65-45, 60% maltodextrin type food fiber;

- 0.00-20.25% skimmed milk powder;

- 0.18-0.50% emulsifier;

- 0.26-0.50% soy lecithin; and

- 0.00-15.00% pieces of toasted almonds with skin.

As can be seen the great differences between the 4 mentioned carob bar recipes, it is with or without milk and with or without almonds.

Carob bar, without milk and without almonds, comprises the following ingredients:

- 33.30-43.85% of vegetable shortening of palm;

- 1.20-5.00% coconut fat;

- 10.00-35.00% carob;

- 0.01-0.04% sweetener;

- 30, 65-45, 60% maltodextrin type food fiber;

- 0.18-0.50% emulsifier; and

- 0.26-0.50% soy lecithin. The bar of carob, without milk and without almonds is said 4 recipes which comprises the fewest ingredients, a total of 7.

The carob bar, with milk and with almonds comprises the following ingredients:

- 33.30-43.85% of vegetable shortening of palm;

- 1.20-5.00% coconut fat;

- 10.00-35.00% carob;

- 0.01-0.04% sweetener;

- 30, 65-45, 60% maltodextrin type food fiber;

- 5,00-20,25% of skim milk powder;

- 0.18-0.50% emulsifier;

- 0.26-0.50% soy lecithin; and

- 0.00-15.00% pieces of toasted almonds with skin.

The bar of carob, with milk and with almonds is said 4 recipes which comprises the largest number of ingredients, a total of 9.

The carob bar, without milk and with almonds, comprises the following ingredients:

- 33.30-43.85% of vegetable shortening of palm;

- 1.20-5.00% coconut fat;

- 10.00-35.00% carob;

- 0.01-0.04% sweetener;

- 30, 65-45, 60% maltodextrin type food fiber;

- 0.18-0.50% emulsifier;

- 0.26-0.50% soy lecithin; and

- 5,00-15,00% pieces of toasted almonds with skin.

Carob bar, with milk and without almonds comprises the following ingredients: - 33.30-43.85% of vegetable shortening of palm;

- 1.20-5.00% coconut fat;

- 10.00-35.00% carob;

- 0.01-0.04% sweetener;

- 30, 65-45, 60% maltodextrin type food fiber;

- 5,00-20,25% of skim milk powder;

- 0.18-0.50% emulsifier; and

- 0.26-0.50% soy lecithin.

The present invention should only be limited by the spirit of the following claims.

Faro, September 6, 2017

Claims

In the first aspect,

Process for the production of carob tree bar comprising sequentially comprising 9 steps: I ^to step

weighing of raw materials

2 ^a step

mixture of fats,

- 33.30-43.85% of vegetable shortening of palm; and

- 1.20-5.00% coconut fat;

in a mill, for 0.25 to 1 hour and at a temperature between 30 and 70 ° C;

and

pre-mix of powders,

- 10.00-35.00% carob; and

- 0.01-0.04% sweetener;

- 30.65-45.60% maltodextrin dietary fiber;

- 0.00-20.25% skimmed milk powder;

- 0.18-0.50% emulsifier;

- 0.26-0.50% soy lecithin; and

- 0.00-15.00% pieces of toasted almonds with skin; in a mill, for from 0.25 to 1 hour and at a temperature between 30 and 70 ° C;

3 ^a step

mixing fat and powders, in a mill for 2 to 12 hours at a temperature between 30 C and 70 ^to be obtained to a particle size with a particle size between 10 and 30μπι;

4 ^a step

the mixture of fats and powders obtained in the previous step for 6 to 24 hours and at a temperature - between 30 and 70 ° C

5 ^a step

quenching of the mixture of fats and powders obtained in the foregoing 2 stages in the temperadora for 1 to 4 hours and at a temperature between 25 to 50 ° C

Step 6

molding the mixture of fats and powders through a mold

Step 7

cooling the carob rod in a cooling tunnel for 0.10 to 0.50 hours, at a temperature between 5 to 18 ° C and with a relative humidity between 30 to 60% relative humidity

Step 8

carob bar demoulding

Step 9

packaging and storage.

Carob rod, made according to the carob rod manufacturing process described in the preceding claim, characterized in that the carob rod comprises:

- 33.30-43.85% of vegetable shortening of palm;

- 1.20-5.00% coconut fat;

- 10.00-35.00% carob;

- 0.01-0.04% sweetener;

- 30, 65-45, 60% maltodextrin type food fiber;

- 0.00-20.25% skimmed milk powder;

- 0.18-0.50% emulsifier;

- 0.26-0.50% soy lecithin; and

- 0.00-15.00% pieces of toasted almonds with skin.

3. Carob bar according to Characterized in that the locust bean bar comprises:

- 33.30-43.85% of vegetable shortening of palm;

- 1.20-5.00% coconut fat;

- 10.00-35.00% carob;

- 0.01-0.04% sweetener;

- 30.65-45.60% maltodextrin type food fiber;

- 5,00-20,25% of skim milk powder;

- 0.18-0.50% emulsifier; and

- 0.26-0.50% soy lecithin.

Carob bar according to claim 2, characterized in that the locust bean bar comprises:

-33.30-43.85% of vegetable shortening of palm;

-1.20-5.00% coconut fat;

-10.00-35.00% carob;

-0.01-0.04% sweetener;

-30.65-45.60% maltodextrin type food fiber; -0.18-0.50% emulsifier; and

-0.26-0.50% soy lecithin.

Carob bar according to claim 2, characterized in that carob rod comprises:

- 33.30-43.85% of vegetable shortening of palm;

- 1.20-5.00% coconut fat;

- 10.00-35.00% carob;

- 0.01-0.04% sweetener;

- 30.65-45.60% maltodextrin type food fiber;

- 5,00-20,25% of skim milk powder;

- 0.18-0.50% emulsifier;

- 0.26-0.50% soy lecithin; and - 4 -

- 5,00-15,00% pieces of toasted almonds with skin.

Carob bar according to claim 2, characterized by carob rod, comprising:

- 33.30-43.85% of vegetable shortening of palm;

- 1.20-5.00% coconut fat;

- 10.00-35.00% carob;

- 0.01-0.04% sweetener;

- 30.65-45.60% maltodextrin type food fiber;

- 0.18-0.50% emulsifier;

- 0.26-0.50% soy lecithin; and

- 5,00-15,00% pieces of toasted almonds with skin. Faro, October 16, 2017