WO2021002815A2

WO2021002815A2 - An industrially produced, new chocolate ball with a long shelf life and the production method thereof

Info

Publication number: WO2021002815A2
Application number: PCT/TR2019/050983
Authority: WO
Inventors: Dilek SENER; Ezgi Gul YILMAZ
Original assignee: Elvan Gida Sanayii Ve Ticaret A.S.
Priority date: 2019-07-01
Filing date: 2019-11-22
Publication date: 2021-01-07
Also published as: BG113438A; WO2021002815A3; TR201909776A2

Abstract

The invention relates to a new chocolate ball with a long shelf life, which is suitable for industrial production as being different from other patisserie products, and to the production method thereof. The invention consists especially of a hollow meringue, a filling material and a cream (chocolate-cocolin) structure covering the entire structure which enables the products such as profiterole and éclair which belong to patisserie field and which are expensive than the standard desserts to take place on the shelves with serial production.

Description

AN INDUSTRIALLY PRODUCED, NEW CHOCOLATE BALL WITH A LONG SHELF LIFE AND THE PRODUCTION METHOD THEREOF

Subject of the Invention and the Technical Field

The invention relates to a new chocolate ball with a long shelf life, which is suitable for industrial production as being different from other patisserie products, and to the production method thereof. The invention consists especially of a hollow meringue, a filling material and a cream (chocolate-cocolin) structure covering the entire structure which enables the products such as profiterole and eclair which belong to patisserie field and which are expensive than the standard desserts to take place on the shelves with serial production.

Known State of the Art

The food products covered with chocolate outside and having a cream filling therein, which are called chocolate balls are a kind of dessert which is prepared by mixing the main ingredients such as flour, margarine, water and egg, by baking this mixture at a predetermined temperature and by depositing filling materials such as cream etc. into the baked dough. In order to enrich the taste, milk and different kinds of additives, different thickening and leavening agents can also be added during the production phase into these products, the similar products of which are known to belong to French patisseries. The entire characteristic of the product to be obtained at the end of the production process is determined by the kind of the material used, and the temperature and duration values of the baking process applied.

In the state of the art, it is required that the external part of the dough balls form a shell during the baking process by baking the prepared dough mixture at a certain temperature (a temperature between 100-200°C) for a certain duration (4-20 minutes) and the internal structure be volumetrically hollow. In this way, the serial production of the chocolate balls with the material type and via the production method determined according to demands, and offering for sale after packaging is an important commercial subject in food sector.

In the state of the art, ganache (cake cream) is used as the filling material inside the chocolate covered balls, and flour, margarine, water, sugar and egg are used in the cookie part thereof. Aromas such as abovementioned chocolate, coffee, orange, peanut, rose, forest fruits, vanilla and caramel are used in said products. Due to their main contents and the feature of the filling material, the chocolate covered products with fillings are not the products which have long shelf life and which can be found in the markets within packaging except for the patisseries and thus, these are high-cost products.

In the state of the art, there are a lot of patents relating to the chocolate covered products with fillings and the production technologies thereof. No patents have been found relating to the production method of the products which are used in said production method, have a long shelf life and are industrially developed, and which have a proper form and do not deform over time thanks to the novelty in the production method and the content used in said chocolate-covered and cream-filled ball products.

The South-Korean patent KR20020076435 describes a chocolate-covered product in the form of a ball which is made by a cake prepared from rice flour. In said patent, the powdery mixture consisting of rice flour, egg, sugar and aromatic additive is baked and the external part thereof is covered with chocolate in a ready, liquid mixture form. This is practical product which people can prepare easily. However, a new chocolate-covered ball type with filing which is suitable for industrial production and has a long shelf life and also the production method thereof are not mentioned in said patent.

The South-Korean patent KR20130071513 describes a ganache-filled patisserie product which is in the form of a ball made via chocolate molds and has a rice cake-covered layer inside. However, a new chocolate-covered ball type with filing which is suitable for industrial production and has a long shelf life and also the production method thereof are not mentioned in said patent.

The Japanese patent JP2001197864 describes a content which is prepared for chocolate- covered cake products. The characteristic of the product described in said patent is that it is a product which can be applied to the cakes covered with chocolate mixture. However, a new chocolate- cove red ball type with filing which is suitable for industrial production and has a long shelf life and also the production method thereof are not mentioned in said patent.

The Japanese patent JPH06181690 describes a chocolate-covered product with multilayers. The characteristic of the product described in said patent is that it is a product which is covered with chocolate mixture and has layered, fluid and non-fluid chocolate parts therein. However, a new chocolate-covered ball type with filing which is suitable for industrial production and has a long shelf life and also the production method thereof are not mentioned in said patent.

Said patents describe different production methods of chocolate-covered balls with filling and the products produced by said methods; however, they do not describe a novel chocolate-covered ball with filling which is similar to the product of the present invention, has a long shelf life and is suitable for industrial production, and the production method thereof.

Technical Problems to be Solved by the Invention

In the new chocolate-covered ball product with filling and the production method thereof according to the invention, it is aimed that the ball or similar food products consisting of a meringue and cream is produced via a new method suitable for industrial production and providing a long shelf life; that it is packaged by using packages with separators or different packages after the production, thus that it can be placed onto the shelves for a long period; and that similar new products can be produced. The chocolate-covered ball product with filling according to the present invention can stay on the shelves for a 6- month period and can be consumed within this period by the end consumer. Thus, a product is produced which is cheap, easily accessible and advantageous for the end consumer.

In the state of the art, the main production method of the chocolate-covered ball product with filling comprises the steps of firstly depositing the meringue dough prepared by mixing flour, sugar, egg and water into tiny balls, then baking the deposited meringue dough on a tray, depositing cream into the inner hollow part of the baked meringue (may have different shapes), and covering the external part thereof with chocolate. After these processes, said product is ready for being packaged.

The first advantage of the production method of the present invention is that it enables serial production which was not possible in the past thanks to certain parameters determined by the invention as the meringue structure is very delicate.

Another advantage of the present invention is that it enables producing products with long shelf life and without form-deformation during its shelf life which could not be provided in the chocolate-covered ball products with filling produced according to the conventional methods. Another advantage of the present invention is that a product can be obtained with a cost suitable for the customer due to serial production.

Another advantage of the present invention is that it is a production method which enables shortening the maturing and baking durations providing the desired features of the meringue.

Another advantage of the present invention is that it has technical pasteurization systems developed for the cream filling deposited into the meringue.

For the foodstuff having a low humidity content such as the chocolate-covered balls with filling and similar products, the storage conditions are the parameters affecting the product quality directly. The solutions are not mentioned in the state of the art about the form- deformation of the products according to the storage conditions.

The drawings will help for a better understanding of the method and the product produced thereby of the present invention.

Description of the Drawings

Fig. 1a shows the schematized form of the processes and the phases the main ingredients of the chocolate-covered ball products with filling of the present invention go through.

Fig. 1b is a cross-sectional view showing the filling parts and the shell on the chocolate ball product produced via the method of the present invention.

Fig. 2 is the production flow diagram of the chocolate ball product produced via the method of the present invention.

Reference Numerals of the Sections and Parts to Serve for Describing the Invention

1- Meringue

1a- Powder content

1b- Meringue dough

1c- Outer shell of the meringue

1d- Gap of the meringue

2- Inner filling material-ganache

2a- Chocolate covering

3- Chocolate ball The steps of the present invention are as follows:

Preparing the meringue dough (210)

Transferring the mixture to the depositor and depositing thereof (220)

Baking the meringue (230)

Preparing and baking the cream (240)

Depositing the cream into the meringue (250)

Covering the outer shell of the meringue with chocolate (260)

- Cooling (270)

Packaging (280).

Detailed Description of the Invention

In the new chocolate-covered and cream-filled ball product and the production method thereof according to the invention, it is aimed that the ball or similar food products consisting of a meringue and cream is produced via a new method suitable for industrial production and providing a long shelf life; that it is packaged by using packages with separators or different packages after the production, thus that it can be placed onto the shelves for a long period; and that similar new products can be produced. The chocolate- covered and cream-filled ball product according to the present invention can stay on the shelves for a 6-month period and can be consumed within this period by the end consumer. Thus, a product is produced which is cheap, easily accessible and advantageous for the end consumer.

In the production method according to the invention of the chocolate-covered and cream- filled ball product which has a long shelf life and is suitable for industrial production, the main ingredients mainly used are flour, margarine, sugar, water, additives (emulsifying, thickening and preserving agents etc.) and egg. In said the chocolate-covered and cream- filled ball products, chocolate, coffee, orange, peanut, rose, forest fruits, vanilla and caramel can be used as aromas in the cream of the inner filling material. Cocoa liquor, vegetable oil, sugar, emulsifier and cocoa powder are used as the main ingredients in the preparation of ganache which is the cream used in the gap within the cookies called as meringue.

Thus, a schematic perspective view of the chocolate-covered and cream-filled ball product which has a long shelf life and is suitable for industrial production is show in Fig. 1. Fig. 2 shows the flow diagram showing the main stages of the production process of the chocolate-covered and cream-filled ball according to the invention.

The chocolate ball (3) product which is produced by the method of the present invention consists of a outer shell of the meringue (1c) and the chocolate covering (2a) covering the external part thereof, and an inner filling material-ganache (2) deposited into the gap of the meringue (1d) inside said outer shell of the meringue (1c).

In the method described, the production stage starts with the step of preparing a powder content (1a) as described in the process flow diagram in Fig. 2. First of all, the powder content (1a) mentioned above, i.e. flour, is weighted in certain grams and mixed. The homogenous powder content (1a) is stirred again by being added onto the pre-mixed water and margarine mixture, then it is stirred again after adding egg into the resulting dough, and the meringue dough (1b) is obtained. Afterwards, this meringue dough (1b) is deposited onto the trays in the form of balls preferably having a weight of 5 to 15 grams.

The meringue dough (1b) and outer shell of the meringue (1c) structure do not have a special main agent. Said meringue dough (1b) only comprises flour, margarine, sugar, water, different additives (emulsifying, thickening and preserving agents etc.) and egg. The meringue dough (1b) preferably having different colors prepared by adding said additives is transferred to the depositor and is deposited onto the trays of different shapes, and is subjected to the baking process by taking into the oven after the maturing process which is performed after the depositing process based on the process conditions. The optimal baking temperature used for the production of the chocolate ball (3) products ranges between preferably 150°C and 250°C (degree Celsius) and the baking period is preferably between 8 and 25 minutes. The meringue dough (1 b) gains its structural properties during baking process. The external part should constitute the outer shell of the meringue (1c) part by being baked, the inner part should be hollow and not sticky and the outer shell of the meringue (1c) have a medium hardness.

After the baking process of the outer shell of the meringue (1c) is completed, optimum parameters are determined for the preparation and pasteurization of the inner filling material-ganache (2) cream to be deposited into the inner gap of the meringue (1d). These parameters are the water activity, humidity, density etc. The production of the inner filling material-ganache (2) in the form of an aromatized (vanilla, milk, cream etc.) pudding is performed by mixing vegetable oil, flour, sugar, egg, margarine, milk and derivatives thereof at predetermined percentages for the cream preparation and by being baked at a temperature ranging between 80-100°C. After this step, the inner filling material-ganache (2) is deposited into the inner gap of the meringue (1d) inside the outer shell of the meringue (1c). Afterwards, chocolate or cocolin product which is the prepared chocolate covering (2a) material is poured onto the outer shell of the meringue (1c) into which the inner filling material-ganache (2) is deposited and as a result of these steps, the chocolate ball (3) which is the final product is produced as to have a 6-month shelf life.

The interactions of the inner filling material-ganache (2) and the outer shell of the meringue (1c) determine the quality of the product. Thanks to this invention, the disadvantages can be eliminated. The chocolate ball (3) which is the final product is transferred to the packaging band by man power or robots. After this step, packaging is performed and the products are transferred for end users.

When the production method of the chocolate ball which has a long shelf life and is suitable for industrial production is considered as a whole process, it comprises the following steps:

Preparing the meringue dough (210)

Transferring the mixture to the depositor and depositing thereof (220)

Baking the meringue (230)

Preparing and baking the cream (240)

Depositing the cream into the meringue (250)

Covering the outer shell of the meringue with chocolate (260)

- Cooling (270)

Packaging (280)

That these stages comprise which steps is described as follows:

Preparing the meringue dough (210): In the production method developed, first of all, the powder content (1a) indicated for the production of chocolate ball (3), namely flour is weighted and sifted. After ensuring the homogeneity of the sifted powder content (1a), the main step is performed for transforming it into the meringue dough (1 b).

Said meringue dough (1b) consists only of flour, margarine, sugar, water, different additives (preserving, thickening and emulsifying agents) and egg. When constituting the meringue structure, the margarine and water is heated preferably at a temperature of 60- 90°C, then the powder content (1a), i.e. flour is added thereon, and the mixture is baked by heating it preferably to a temperature of 80-100°C. After the baking process, the dough has a cake dough form. The dough is cooled to a temperature of 40-50°C and egg is added onto the dough mixture in order to be deposited as a meringue and to provide a meringue with desired properties. After adding the egg, the mixture is stirred and a soft and low-viscosity meringue dough (1 b) is obtained. Said meringue dough (1 b) does not have a special main agent.

Transferring the mixture to the depositor and depositing thereof (220): At this step, the meringue dough (1b) is transferred to the depositor and deposited onto the trays in the form of tiny balls preferably having a weight of 5 and 15 grams. The deposited parts are preferably in the form of round balls.

Baking the meringue (230): At this step, the meringue dough (1b) deposited onto the trays are baked in order to provide a desired shape and to have a hollow and fluffy structure via a suitable baking method. The optimal baking temperature used for the production of said chocolate ball (3) products ranges between preferably 150°C and 250°C (degree Celsius) and the baking period is preferably between 8 and 25 minutes. The meringue dough (1b) gains its structural properties during baking process. When the external part constitutes the outer shell of the meringue (1c) part by being baked, the inner part becomes hollow and not sticky, the baking process of the meringue (1) is completed.

Preparing and baking the cream (240): At this step, the cream to be filled into the meringue (1), namely the inner filling material-ganache (2) is prepared via a special process. The cream may be prepared in the form of a pudding, optionally with an aroma (milk, vanilla, forest fruits). The baking process is performed after the main ingredients used for preparing the cream are mixed homogenously. The production of the inner filling material-ganache (2) in the form of an aromatized (vanilla, milk, cream etc.) pudding is performed by mixing vegetable oil, flour, sugar, egg, margarine, milk and derivatives thereof at predetermined percentages for the cream preparation and by being baked at a temperature ranging between 80-100°C. Thanks to the special techniques (pasteurization etc.) used for creams, the quality of the product is further improved.

Depositing the cream into the meringue (250): After the baking process of the meringue (1) is completed, the cream, namely the inner filling material-ganache (2) is deposited into the gap of the meringue (1d) which is the part between the outer shell of the meringue (1) and core of the meringue (1).

Covering the outer shell of the meringue with chocolate (260): After depositing the inner filling material-ganache (2) cream into the gap of the meringue (1 d), a chocolate covering (2a), preferably chocolate or cocolin is poured onto the outer shell of the meringue (1c), and as a result of this step, the chocolate ball (3) which is the final product is produced as to have a 6-month shelf life.

Cooling (270): The produced chocolate ball (3) is passed through the cooling tunnel and the product gains its final form. After this step, the chocolate ball (3) products are transferred to the band for packing and packaging.

Packaging (280): The final product, namely the chocolate ball (3) is transferred to the packaging band by man power or robots. After this step, packaging is performed and the products are transferred for end users.

Industrial Applicability of the Invention

In the new chocolate-covered and cream-filled ball product and the production method thereof according to the invention, it is aimed that the ball or similar food products consisting of a meringue and cream is produced via a new method suitable for industrial production and providing a long shelf life; that it is packaged by using packages with separators or different packages after the production, thus that it can be placed onto the shelves for a long period; and that similar new products can be produced.

The chocolate ball product of the present invention has a 6-month shelf life and can be consumed within this period by the end consumer. By developing the production method of said product, a product is produced which is cheap, easily accessible and advantageous for the end consumer. That various types of the fruit aromas, the additives and the syrups can be selected provides a wide product range will enable producing profiterole, eclair and similar foodstuff with a long shelf life.

Claims

1. A production method of a chocolate ball product which can be used in food industry, has a long shelf life and is suitable for industrial production, characterized by the following steps:

Preparing the meringue dough (210)

T ransferring the mixture to the depositor and depositing thereof (220)

Baking the meringue (230)

Preparing and baking the cream (240)

Depositing the cream into the meringue (250)

Covering the outer shell of the meringue with chocolate (260)

- Cooling (270)

Packaging (280).

2. Method according to claim 1 , characterized in that, at the step of preparing a meringue dough (210), flour which is indicated as the powder content (1a) for the production of the chocolate ball (3) and sugar are weighted in predetermined grams; they are sifted in order to provide homogeneity; then flour is added as the powder content (1a) after heating the margarine and water preferably at a temperature of 60-90°C to provide a meringue dough (1 b); said mixture is baked by being heated preferably to a temperature of 80-100°C; after the baking process, the temperature of the dough is cooled preferably to 40-50°C; egg is added into the dough mixture in order to provide a dough with desired properties; and the mixture is stirred in order to provide a dough with low-viscosity.

3. Method according to claim 2, characterized in that, at the step of transferring the mixture to the depositor and depositing thereof (220), the meringue dough (1 b) is transferred to the depositor and is deposited onto the trays in the form of tiny balls preferably having a weight of 5 and 15 grams.

4. Method according to claim 3, characterized in that, at the step of baking the meringue (230), following the depositing process of the meringue dough (1b) deposited on the trays, the meringue dough (1 b) is transferred into an oven and is subjected to a baking process under certain conditions by heating preferably at a temperature of 150-250°C (degree Celsius) and for baking period of preferably between 8 and 25 minutes; and the meringue dough (1b) gains a meringue (1) form by being baked.

5. Method according to claim 4, characterized in that, at the step of preparing and baking the cream (240), the production of the inner filling material-ganache (2) with an aroma (vanilla, milk, cream etc.) is performed by mixing vegetable oil, flour, sugar, egg, margarine, milk and derivatives thereof for the cream preparation and by being baked at a temperature ranging preferably between 80-100°C; and thanks to the special techniques (pasteurization etc.) used for creams, the quality of the product is further improved.

6. Method according to claim 5, characterized in that, at the step of depositing the cream into the meringue (250), after the baking process of the meringue (1) is completed, the inner filling material-ganache (2) cream is deposited into the gap of the meringue (1d) which is the part between the outer shell of the meringue (1) and core of the meringue (1).

7. Method according to claim 6, characterized in that, at the step of covering the outer shell of the meringue with chocolate (260), a chocolate covering (2a), preferably chocolate or cocolin is poured onto the outer shell of the meringue (1c), and as a result of this step, the chocolate ball (3) which is the final product is produced.

8. Method according to claim 7, characterized in that, at the step of cooling (270), the produced chocolate ball (3) is passed through the cooling tunnel.

9. Method according to claim 8, characterized in that, at the step of packaging (280), the final product, namely the chocolate ball (3) is transferred to the packaging band preferably by man power or robots; and packaging is performed.