WO2023025949A1

WO2023025949A1 - Confectionery product

Info

Publication number: WO2023025949A1
Application number: PCT/EP2022/073813
Authority: WO
Inventors: Murray James SWAIN; Borislav Zdravkov BORISOV
Original assignee: Société des Produits Nestlé S.A.
Priority date: 2021-08-27
Filing date: 2022-08-26
Publication date: 2023-03-02
Also published as: AU2022334817A1; CA3228502A1

Abstract

The present invention relates to a confectionery product comprising a filling cream layer. The present invention relates to a process which can be used for the preparation of such aconfectionery product.

Description

CONFECTIONERY PRODUCT

FIELD OF THE INVENTION

The present invention relates to a confectionery product comprising a filling cream layer. In particular, the present invention relates to a process for the preparation such a confectionery product.

BACKGROUND OF THE INVENTION

Confectionery products comprising one or more filling cream layers; for example wafer sandwiches which comprise two or more wafer layers with one or more filling cream layers sandwiched between the wafers, are well known. Said filling cream layers generally comprise one or more fats and one or more sweeteners and function to impart variation in flavour and mouthfeel as well as improving the quality and acceptability to the consumer of the final confectionery product. Known confectionery products typically comprise a thin layer of filling cream sandwiched between thin layers of an edible substrate, such as thin wafer layers. In order to provide a final confectionery product, typically a plurality of thin layers of filling cream are sandwiched alternately between layers of edible substrates such as wafers. Typically such confectionery products are made by book-cutting (i.e. book-cut products), whereby the filling cream is spread onto large sheets of edible (typically baked) substrates, and covered with a second sheet of edible substrate, and repeated in order to produce a “book” comprising alternate layers of edible substrate and cream, with the edible substrate layers on external faces of the book. The book is then cut into a plurality of cut products. The cut products themselves may be the final confectionery product, or optionally, the cut products may be further processed (e.g. by the addition of a chocolate coating), in order to produce the confectionery product.

Processes for preparing such confectionery products comprising a filling cream sandwiched between two edible substrate layers, are typically limited as to the depth/thickness of the filling cream layer. Particularly, it has been found that attempts to increase the depth of the filling cream layer have been especially problematical due to difficulties encountered with adhesion of the filling cream. Such adhesion difficulties result in the book cutting process causing delamination of the layers, resulting in the generation of significant waste products in the process, and rendering the process unsuitable for commercial large-scale production.

A thick filling cream layer may be desirable in order to provide a confectionery product with a more desirable, luxurious or indulgent mouthfeel, texture and/or taste to the consumer. However, it has been found that known processes for producing confectionery products having a thick filling cream layer present difficulties when attempting to achieving a greater thickness (e.g. 3.5 mm or greater) of the filling cream layer. In order to achieve optimum adhesion, it is desirable to reduce fat crystallisation prior to layering the filling cream onto the edible substrate. However, control of fat crystallisation at this stage has hitherto been achieved by maintaining the filling cream at a relatively high temperature at the time of application to the substrate. At the relatively high temperatures used in conventional processes in order to ensure that fat crystallisation is suitably controlled, the viscosity of the filling cream is too low, thereby causing the filling cream to run off the edge of the substrate during the layering process, or being compressed out by the application of a second edible substrate layer over the first edible substrate layer. This results in a significant wastage of the filling cream as well as making the downstream processing of the confectionery product difficult due to the inconsistent layer heights, and well as the additional expense of removing the filling cream from the manufacturing equipment. If the temperature is too low, issues with the layering and delamination, as well as blockage of the layering apparatus may be encountered. Such processes are therefore typically used for thin layers of filling cream (such as less than 1 .0 mm). As indicated above, the resulting products are typically made up from a plurality of edible substrate layers and such thin filling cream layers.

As indicated above, a confectionery product having a thicker layer of filling cream would nevertheless be desirable in certain premium products, since the consumers generally perceive such products with thicker cream layers as being more indulgent and luxurious. There is therefore an ongoing need for new improved processes of producing such confectionery products with thick filling cream layers without the aforementioned problems and without incurring excessive waste.

Through extensive investigations, the applicant has now surprisingly found that a process whereby a filling cream mixture is cooled under certain conditions can provide a cooled filling cream mixture with a sufficient viscosity to be effectively layered to provide a thick filling cream layer, and minimising or avoiding delamination, and thereby reducing waste. The presently disclosed process is therefore able to produce confectionery products with significantly greater thickness of filling cream.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, there is provided a process for preparing a confectionery product comprising a filling cream layer, the process comprising:

(a) providing a filling cream mixture comprising one or more added fats, one or more added sweeteners, and optionally one or more flavourings; (b) stirring and heating the mixture to a temperature of at least 55°C to provide a heated filling cream mixture;

(c) stirring and cooling the heated mixture to a temperature of from: 20°C to 45°C at a cooling rate of less than 5°C per minute and at a shear rate of from 1 s^-1 to 250 s’¹, to provide a cooled filling cream mixture having a viscosity of at least 6000 cP; and;

(d) applying the cooled filling cream mixture onto a first edible substrate, to form a filling cream layer having a thickness of at least 3.5 mm;

(e) placing a second edible substrate on the filling cream layer to form a book; and

(f) cutting the book to form a plurality of cut products, and optionally processing the cut product to form a confectionery product.

The invention further provides a confectionery product, wherein the confectionery product is produced by a process according to the first aspect.

Further provided is a book-cut confectionery product, wherein the confectionery product comprises two or more edible substrate layers and one or more filling cream layers in between the edible substrate layers, wherein: the one or more filling cream layers comprise one or more added fats, one or more sugars, and optionally one or more flavourings; the one or more filling cream layers have a thickness of at least 3.5 mm, wherein the edible substrate layers and one or more filling cream layers are as defined herein.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, unless otherwise indicated, weights are given as a weight percent.

As used herein, unless otherwise indicated, viscosity measurements refer to measurements obtained at the specified temperature.

As used herein, unless otherwise indicated, the term “added sweetener” or “added sugar” have the standard meaning in the art and refers to a sweetener or sugar which is not inherently present in other ingredients. In line with the recognised meaning in the art, naturally occurring sugars are found naturally in foods such as cocoa, fruit (fructose) and milk (lactose). An added sugar therefore refers to a sugar or sweeteners put in foods during preparation or processing. For example, the US FDA has defined added sugars as: “sugars that are either added during the processing of foods, or are packaged as such”, and include sugars (free, mono and disaccharides), syrups, naturally occurring sugars that are isolated from a whole food and concentrated so that sugar is the primary component (e.g., fruit juice concentrates), and other caloric sweeteners.

The added fat component in the filling cream layer may be defined by a particular weight or weight range of solid fat, trans-fat or saturated fatty acids per 100 g. By this, it is meant that the solid fat, trans-fat or saturated fatty acids content in the added fat component is present in the weight or weight range relative to the added fat component.

As used herein, unless otherwise indicated, the term “added fat” refers to fat that is not inherently present in other ingredients, such as in the flavourings (e.g. cocoa powder contains fat).

As used herein, unless otherwise indicated, the term “added water” refers to water that is not inherently present in other ingredients.

As used herein, unless otherwise indicated, the term “book-cut” refers to a process and a corresponding product whereby a “slab” (i.e. “book”) of the confectionery product is prepared (for example a confectionery product comprising at least one filling cream layer sandwiched between two layers of edible substrate), and cut to form a plurality of units of the confectionery product. A book-cut confectionery product is distinguishable from, for example, a cream-filled confectionery product (such as a cream-filled biscuit), in that in the latter, the cream filling is applied to individual unit substrates (e.g. biscuit). Generally, the filling in such a cream-filled biscuit is typically applied only to the centre of the biscuit layers and is not distributed across the entirety (e.g. to the edge) of the surface of the biscuit layers. Typically, a book-cut product comprises a filling cream which is uniformly spread across to the edge of the substrate layers.

Filling cream mixture

According to any embodiment of the present invention, the filling cream mixture comprises one or more added fats, one or more added sweeteners, and optionally one or more flavourings. The filling cream preferably contains no added water. In a preferred embodiment, the filling cream mixture is substantially free of water. Preferably the filling cream mixture comprises less than 5 wt.% water, preferably less than 4 wt.% water, more preferably less than 3 wt.% water, particularly less than 2 wt.% water, and most particularly less than 1 wt.% water. Fats and Added Fats

Within the context of the present invention the term "fat" as used herein denotes a hydrophobic material which is also edible. Thus, fats are edible material that are substantially immiscible with water and which may comprise one or more solid fat(s), liquid oil(s) and/or any suitable mixture(s) thereof. The term "solid fat" denotes edible fats that are solid at the stated temperature and the terms "oil" or "liquid oil" (unless the context indicates otherwise) both denote edible oils that are liquid at the stated temperature.

In an embodiment, the filling cream mixture has a total fat content of from 20 wt.% to 45 wt.%, preferably from 30 wt.% to 35 wt.%, and most preferably about 33 wt.%. In one embodiment, the filling cream mixture comprises from 15 wt.% to 40 wt.%, preferably from 25 wt.% to 35 wt.%, most preferably from 28 wt.% to 32 wt.% of the one or more added fats. It will be appreciated that the total amount of fat in the filling cream mixture may not be identical to the total amount of added fat due to small amounts of fat being present in other optional components of the filling cream mixture, for example, chocolate.

In an embodiment, the one or more added fats have a solid fat content of from: 15 g/100 g to 60 g/100 g, preferably from 20 g/100 g to 50 g/100 g, and most preferably from 25 g/100 g to 35 g/100 g, at 20°C.

In an embodiment, the one or more added fats have a solid fat content of: from 10 g/100 g to 50 g/100 g, preferably from 15 g/100 g to 40 g/100 g, and most preferably from 16 g/100 g to 26 g/100 g at 25°C.

In an embodiment, the one or more added fats have a solid fat content of: from 5 g/100 g to 30 g/100 g, preferably from 10 g/100 g to 25 g/100 g, and most preferably from 10 g/100 g to 18 g/100 g, at 30°C.

In an embodiment, the one or more added fats have a solid fat content of: from 2 g/100 g from 20 g/100 g, preferably from 4 g/100 g to 15 g/100 g, and most preferably from 6 g/100 g to 12 g/100 g, at 35°C.

In a particularly preferred embodiment, the one or more added fats have a solid fat content at 20°C as described above, a solid fat content at 25°C as described above, a solid fat content at 30°C as described above, and a solid fat content at 35°C as described above.

The solid fat content of the one or more added fats is measured according by pulsed NMR according to ISO 8292-1 :2008 (“Animal and vegetable fats and oils — Determination of solid fat content by pulsed NMR — Part 1 : Direct method”), measurement protocol 1 D, parallel method.

In one embodiment, the one or more added fats comprise from: 30 g/100 g to 70 g/100 g saturated fatty acids, preferably from 40 to 60 g/100 g saturated fatty acids, more preferably from 40 g/100 g to 50 g/100 g or from 40 g/100 g to 45 g/100 g, and most preferably about 43 g/100 g of saturated fatty acids. In one embodiment, the one or more added fats comprise: less than 2 g/100 g trans fats, and preferably less than 1 g/100 g trans fats. In one embodiment, the one or more added fats are interesterified. In one embodiment, the one or more added fats consist of palm oil, preferably interesterified palm oil.

Added Sweeteners

The filling cream mixture of the invention comprises one or more added sweeteners. In one embodiment, the one or more added sweeteners comprise saccharides (preferably chosen from sucrose, glucose (dextrose monohydrate or anhydrous), galactose, lactose, maltose, fructose, corn syrup, and polydextrose), and/or polyols (preferably chosen from sorbitol, mannitol, maltitol, isomalt, xylitol or erythritol).

In one embodiment, the one or more added sweeteners comprise mono, di-, or polysaccharides. Preferred monosaccharides comprise fructose, glucose (dextrose monohydrate or anhydrous) and/or galactose. Preferred disaccharides comprise sugar (sucrose) of any particle size (powder, caster or granulated), lactose and/or maltose.

Preferred polysaccharide(s) include: starches from any suitable origin (such as corn, wheat, potato or similar well known sources); high amylose starches; hydrolyzed starches (such as dextrins and/or maltodextrins), pre-gelatinised starches; natural or modified starches; isomaltose, maltulose, mannose, ribose galactose, trehalose; starch derivatives including glucose syrup with a DE above 20, maltodextrins with a DE below 20; polydextrose; and mixtures thereof.

In one embodiment, the one or more added sweeteners comprise polyols, which are preferably chosen from sorbitol, mannitol, maltitol, isomalt, xylitol or erythritol.

Preferably, the one or more added sweeteners comprise mono or di-saccharides. In a preferred embodiment, the one or more added sweeteners comprise sugar (sucrose). In a particularly preferred embodiment, the one or more added sweeteners comprises, consists of, or consists essentially of sugar (sucrose). In one embodiment, the mixture comprises: from 30 wt.% to 65 wt.%, preferably 40 wt.% to 60 wt.%, most preferably 45 wt.% to 60 wt.%, of the one or more added sweeteners.

Other Ingredients

In one embodiment, the filling cream mixture comprises wafer rework. It will be understood that the term “wafer rework” used herein has the standard meaning of broken pieces or cuttings of wafer that are recovered from the cutting and processing of a wafer book into a final confectionery product. In a preferred embodiment the filling cream mixture comprises wafer rework in an amount of: from 3 wt.% to 20 wt.%, and more preferably in an amount of from 5 wt.% to 15 wt.%.

The filling cream mixture may optionally comprise one or more flavourings depending on the particular flavour desired for the final confectionery product. Such flavourings include, but are not limited to, cocoa powder, chocolate, cream powder, cheese powder, milk powder, salt, maltodextrin, skimmed milk powder, full cream milk powder (FCMP), whey powder, natural or synthetic flavours, and natural or artificial colours.

Preparation of a Cooled Filling Cream Mixture

The process of preparing the cooled filling cream mixture that is applied to an edible substrate, comprises first stirring and heating the initial filling cream mixture to a temperature of at least 55°C to provide a heated filling cream mixture. Preferably the mixture is heated to a temperature of: from: 55°C to 80°C, from 60°C to 70°C, from 62°C to 68°C, from 64°C to 66°C, and most preferably about 65°C. The purpose of this heating and stirring stage is to ensure the substantially complete, or complete, melting of the fats in the filling cream mixture.

The heated filling cream mixture is then stirred and cooled to a temperature of: from 20°C to 45°C at a cooling rate of less than 5°C per minute and at a shear rate of from 1 s^-1 to 250 s’¹. Conventionally, cooling is carried out at a faster rate and stirred at a higher shear rate. The inventors surprisingly found that a lower cooling rate and a lower shear rate as compared with conventional processes significantly reduced the extent of fat crystallization during the cooling process, thus providing a cooled filling cream mixture with suitable viscosity for application to an edible substrate (such as a wafer sheet) to provide a thick filling cream layer. The process of the present invention may also advantageously reduce or ameliorate wastage due to delamination. Without being bound by theory, it is considered that the low shear rate reduces the number of fat crystals that come into contact with the cold surface of the heat exchanger, thus reducing the level of crystal formation. In some embodiments, the heated filling cream mixture is cooled to a temperature of: from 30°C to 40°C, preferably from 32°C to 38°C, and more preferably from 34°C to 36°C. In a particularly preferred embodiment, the mixture is cooled to a temperature of about 35°C.

In some embodiments, the shear rate is from 1 s^-1 to 200 s’¹, preferably 1 s^-1 to 100 s’¹, and more preferably 1 s^-1 to 50 s’¹. In particularly preferred embodiments, the shear rate is from 1 s'¹ to 20 s'¹ from 1 s^-1 to 10 s’¹, from 3 s^-1 to 7 s’¹, or from 4 s^-1 to 6 s’¹. In a most preferred embodiment, the shear rate is about 5 s’¹.

In some embodiments, the heated mixture is cooled in a first heat exchanger to an intermediate temperature, following by being further cooled in a second heat exchanger to the layering temperature. In such embodiments, the intermediate temperature may preferably be: from 40°C to 60°C, more preferably from 45°C to 55°C, and most preferably about 50°C.

In some embodiments, the heated mixture is cooled at a rate of less than 5°C per minute, less than 4°C per minute, preferably less than 3°C per minute, and more preferably less than 2.5°C per minute. In particularly preferred embodiments, the heated mixture is cooled between 0.5- 5°C per minute, preferably between 1-3°C per minute more preferably between 1-2.5°C per minute.

The viscosity of the cooled filling cream mixture at the cooled temperature is at least 6000 cP (1 cP = 1 mPa-s). Preferably the cooled filling cream mixture has a viscosity of: from 6000 cP to 15000 cP. In some embodiments, the cooled filling cream mixture has a viscosity of: from 7000 cP to 14000 cP, from 7000 cP to 13000 cP, from 7000 cP to 12000 cP, from 7000 cP to 11000 cP, from 8000 cP to 11000 cP, from 9000 cP to 11000 cP. In a particularly preferred embodiment, the viscosity of the cooled filling cream mixture (i.e. at the cooled temperature) is about 10000 cP.

As shown by the comparative example, when the cream viscosity is below 6000 cP it was not possible to obtain the desired cream filling height and on application to the edible substrate the cream leaked off the side. Above 15000 cP, the cream becomes too thick to layer successfully and causes issues in the process (blocking machinery, etc.). Additionally, above 15,000 cP the cream becomes unable to flow properly and causes delamination between the cream and the edible substrate.

Preferably, the viscosity was measured using a Physica MCR302 Rheometer by Anton Paar with a PP75/s (sandblasted probe) geometry and the following method: The height of the plate was reduced to 1 mm once sample inserted prior to starting the test. The viscosity was measured using the following method: The sample was held at starting temperature (65°C for 30 minutes) at a shear rate of 5 s^-1 for the first interval. The shear rate is inputted into the rheometer as a parameter that is controlled by the rheometer. The next interval cooled the sample from 65 to 35 °C at a cooling rate of 3°C/M inute. The final interval held the sample at 35 °C at a shear rate of 5 s^-1 whilst the viscosity was measured.

Edible Substrate

It will be appreciated that the term “edible substrate” refers to any material suitable for consumption on which it is possible to apply the filling cream mixture to form a layer.

In preferred embodiments, the edible substrate is a baked foodstuff. The baked foodstuff is typically sweet, although could comprise low quantities of sugar as discussed, herein, or in some instances, may be savoury. Preferred baked foodstuffs comprise baked grain foodstuffs which includes foodstuffs that comprise cereals and/or pulses. Baked cereal foodstuffs are more preferred, most preferably baked wheat foodstuffs such as wafer(s) and/or biscuit(s). In a particularly preferred embodiment, the baked foodstuffs are wafer sheets. Where the edible substrate is a wafer sheet, it is preferred that the thickness of the filling cream layer is measured between the cores of the wafer sheets.

Wafers are baked products which are made from wafer batter and have crisp, brittle and fragile consistency. They are thin, with an overall thickness usually of: < 1 to 4 mm and typical product densities range from 0.1 to 0.3 g/cm³. The surfaces may be precisely formed, following the surface shape of the plates between which they were baked. They often carry a pattern on one surface or on both. Wafers may also be produced by extrusion. Two basic types of wafer are described by K.F. Tiefenbacher in "Encyclopaedia of Food Science, Food Technology and Nutrition p 417-420 - Academic Press Ltd London - 1993":

1) No- or low-sugar wafers. The finished biscuits contain from zero to a low percentage of sucrose or other sugars. Typical products are flat and hollow wafer sheets, moulded cones or fancy shapes.

2) High-sugar wafers. More than 10% of sucrose or other sugars are responsible for the plasticity of the freshly baked sheets. They can be formed into different shapes before sugar recrystallization occurs. Typical products are moulded and rolled sugar cones, rolled wafer sticks and deep-formed fancy shapes.

In a particularly preferred embodiment, the confectionery product consists of a filling cream layer sandwiched between two wafer layers. As discussed above, the confectionery product of the invention is book-cut, that is, it is formed by cutting a larger product (i.e. book) into plurality of smaller pieces. In a preferred embodiment, the further processing of the cut book comprises enrobing each of the pieces in chocolate.

Layering of Confectionery Product

According to the invention, the cooled filling cream mixture is applied onto a first edible substrate to form a filling cream layer having a thickness of at least 3.5 mm. A second edible substrate is then placed on the filling cream layer to form a “book”, that is, a product comprising filling cream layer sandwiched between two edible substrate layers (i.e. S1-FC-S2, where Si and S2 are first and second substrate layers and FC is a filling cream layer). As used herein the term “book” may comprise two or more layers of edible substrate with one or more filling cream layers sandwiched between each edible substrate layer. Such a book may consist of two edible substrate layers and one filling cream layer or may consist of a plurality of filling cream layers. For example, a book may comprise two filling cream layers (e.g. S1-FC1-S2-FC2, or S1-FC1-S2-FC2-S3), three filling cream layers (e.g. S1-FC1-S2-FC2-S3-FC3-S4 or S1-FC1-S2-FC2-S3-FC3-S4), four filling cream layers (e.g. S1-FC1-S2-FC2-S3-FC3-S4-FC4 or S1-FC1-S2-FC2-S3-FC3-S4-FC4-S5), or more than four filling cream layers. The substrates S_n may be the same or different (preferably the same), and, where a plurality of filling cream layers is used, each filling layer may be the same or different (e.g. different flavours and/or different thicknesses). It should be noted that where a plurality of filling cream layers are used, at least one of the filling cream layers has a thickness of at least 3.5 mm. In some embodiments the filling cream thickness is from 3.5 mm to 15.0 mm, from 3.5 mm to 12 mm, from 3.5 mm to 10 mm, from 3.5 mm to 8 mm, from 3.5 mm to 6 mm, and the other filling layers may be less thick (e.g. less than 3.5 mm). In a particularly preferred embodiment, at least one of the filling cream layers has a thickness of 3.5 mm or greater (preferably from 3.5 mm to 5.0 mm, more preferably from 3.8 mm to 4.8 mm, particularly from 3.9 mm to 4.5 mm, and most preferably from 4.0 mm to 4.2 mm), and the other filling layers may be less thick (e.g. less than 3.5 mm).

Preferably, the confectionery product of the present invention comprises one or two filling cream layers, and more preferably one filling cream layer. Following an optional cooling process, the book is then cut into a plurality of units of the confectionery product. Alternatively, the plurality of units may be optionally further processed (e.g. by enrobing in chocolate) to form the final confectionery product.

Where the book is cooled prior to cutting, the cooling may take place at a temperature of: from 5°C to 20°C, preferably from 10°C to 15°C, and most preferably about 12°C. In preferred embodiments, the filling cream layer has a thickness of: 3.8 mm to 14.0 mm, preferably 3.9 mm to 13.0 mm, preferably 4.0 mm to 12 mm, preferably 4 mm to 10 mm, preferably 4 mm to 8mm, more preferably from 4 mm to 6 mm. In particularly preferred embodiments, the filling cream layer has a thickness of: 3.5 mm to 5.0 mm, preferably 3.8 mm to 4.8 mm, preferably 3.9 mm to 4.5 mm, and more preferably 4.0 mm to 4.2 mm. In a particularly preferred embodiment the filling cream layer has a thickness of about 4.0 mm.

In some embodiments, the process of the invention further comprises applying further cooled filling cream mixture to the second edible substrate to form a second filling cream layer and placing a third edible substrate on the second filling cream layer to form a multilayer book. These two steps may optionally be repeated to provide three or more filling cream layers sandwiched between edible substrate layers. In this way, confectionery products with a plurality of filling cream layers as described above can be produced.

Confectionery Product

In another aspect of the invention, a book-cut confectionery product is provided, comprising two or more edible substrate layers and one or more filling cream layers in between the edible substrate layers, wherein: the one or more filling cream layers comprise one or more added fats, one or more sugars, and optionally one or more flavourings; the one or more filling cream layers have a thickness of at least 3.5 mm, wherein the one or more filling cream layers are as defined above.

As will be appreciated from the disclosure above, a “book-cut” confectionery product refers to a product that is obtained by cutting a book made up of one or more filling cream layers and two or more edible substrate layers as described above. A characteristic feature of book-cut confectionery products is that the filling cream layers extend to the edge of the edible substrate layers, producing a substantially uniform edge.

The edible substrate layers are preferably baked foodstuffs and are preferably wafers.

A preferred book-cut confectionery product according to the invention comprises a layered substrate and filling cream structure as described above, which is coated in chocolate. More preferably a book-cut confectionery product according to the invention comprises a layered wafer and filling cream structure as described above (preferably a wafer-filling cream-wafer structure), which is coated in chocolate.

Examples The present invention will be further understood by the following examples. The examples are illustrative in nature and should not be understood to limit the subject matter of the present disclosure.

Four different initial filing cream mixtures with different flavours were formulated, the ingredients of which are shown in Table 1 below. All mixtures had a total fat content of 33 wt.%:

Table 1

The properties of the added fat IV56ie is shown below in Table 2. As above, solid fat content is measured according by pulsed NMR according to ISO 8292-1 :2008 (“Animal and vegetable fats and oils — Determination of solid fat content by pulsed NMR — Part 1 : Direct method”), measurement protocol 1 D, parallel method.

Table 2

The above filling cream mixtures were heated to 65°C in a jacketed tank with stirring. The mixtures were then cooled in a first heat exchanger (T100 heat exchanger, IBC Technologies) at a cooling rate of 1 °C per minute and a shear rate of 5 s^-1 to a temperature of 50°C. The filling cream mixture was then further cooled in a second heat exchanger (T450 heat exchanger, IBC Technologies) at a cooling rate of 1 °C per minute to a temperature of 35°C. The resulting cooled filling cream mixture was determined to have a viscosity of about 10000 cP, which allowed the successful application of the mixture onto a wafer sheet to give a filling cream layer with a thickness of approximately 4.0 mm. A second wafer sheet was applied to the top of the filling cream layer to form a wafer book. The wafer book was cooled at 12°C for 22 minutes and subsequently cut to provide a book-cut confectionery product with a filling cream layer having a thickness of 4.0 mm, which is greater than achievable using conventional processes.

The viscosity was measured using a Physica MCR302 Rheometer by Anton Paar with a PP75/s (sandblasted probe) geometry and the following method: The height of the plate was reduced to 1mm once sample inserted prior to starting the test. The viscosity was measured using the following method: The sample was held at starting temperature (65°C for 30 minutes) at a shear rate of 5 s^-1 for the first interval. The shear rate is inputted into the rheometer as a parameter that is controlled by the machine. The next interval cooled the sample from 65 to 35 °C at a cooling rate of 3°C/M inute. The final interval held the sample at 35 °C at a shear rate of 5 s^-1 whilst the viscosity was measured.

Comparative Example 1

The salted caramel filling was made according to Table 1. When cooled at a higher rate than 5 °C/Minute with a shear rate of above 250 s^-1 the viscosity at layering was below 5000 cP. This resulted in a cream that did not set properly and the filling cream layer thickness was below the minimum target height of 3.5 mm.

Comparative Example 2

Three different filing cream mixtures with different flavours were formulated, the ingredients of which are shown in Table 3 below:

Table 3

These fillings were heated 45°C to provide a heated filling cream mixture, before this mixture was sent to a mixing unit at 45 °C. Following this the heated cream mixture was layered onto wafer sheets before cooling in a spiral cooler at 10 °C for 15 minutes before book cutting. The resulting wafer books suffered from excessive delamination and reduced cream filling height due to improper setting of the cream after cooling. Hence, the too low initial heating temperature and the non-staged cooling provided an inadequate product.

Various aspects and embodiments of the invention are further described by reference to the following numbered clauses: 1 . A process of preparing a confectionery product comprising a filling cream layer, the process comprising:

(a) providing a filling cream mixture comprising one or more added fats, one or more added sweeteners, and optionally one or more flavourings;

(b) stirring and heating the mixture to a temperature of at least 55°C to provide a heated filling cream mixture;

(c) stirring and cooling the heated mixture to a temperature of: from 20°C to 45°C at a cooling rate of less than 5°C per minute and at a shear rate of from 1 s^-1 to 250 s’¹, to provide a cooled filling cream mixture having a viscosity of at least 6000 cP; and; (d) applying the cooled filling cream mixture onto a first edible substrate, to form a filling cream layer having a thickness of at least 3.5 mm;

2. A process according to clause 1 , wherein step (e) further comprises:

(e-i) applying the cooled filling cream mixture to the second edible substrate to form a second filling cream layer, and

(e-ii) placing a third edible substrate, on the second filling cream layer to form a multilayer book; and

(e-iii) optionally repeating (e-i) and (e-ii) one or more times.

3. A process according to clause 1 or clause 2, wherein the edible substrate is a baked foodstuff, preferably a wafer sheet.

4. A process according to any preceding clause, further comprising cooling the book prior to step (f).

5. A process according to the preceding clause wherein cooling the book or stack of two or more books is carried out at a temperature of from: 5°C to 20°C, preferably from 10°C to 15°C, and most preferably about 12°C.

6. A process according to any preceding clause, wherein the mixture has a total fat content of: from 20 wt.% to 45 wt.%, preferably from 30 wt.% to 35 wt.%, and most preferably about 33 wt.%.

7. A process according to any preceding clause, wherein the mixture comprises: from 15 wt.% to 40 wt.%, preferably from 25 wt.% to 35 wt.%, most preferably from 28 wt.% to 32 wt.% of the one or more added fats.

8. A process according to any preceding clause, wherein the one or more added fats have a solid fat content of: from 15 g/100 g to 60 g/100 g, preferably from 20 g/100 g to 50 g/100 g, and most preferably from 25 g/100 g to 35 g/100 g, at 20°C.

9. A process according to any preceding clause, wherein the one or more added fats have a solid fat content of: from 10 g/100 g to 50 g/100 g, preferably from 15 g/100 g to 40 g/100 g, and most preferably from 16 g/100 g and 26 g/100 g, at 25°C. 10. A process according to any preceding clause, wherein the one or more added fats have a solid fat content of: from 5 g/100 g to 30 g/100 g, preferably from 10 g/100 g to 25 g/100 g, and most preferably from 10 g/100 g to 18 g/100 g, at 30°C.

11. A process according to any preceding clause, wherein the one or more added fats have a solid fat content of: from 2 g/100 g to 20 g/100 g, preferably from 4 g/100 g to 15 g/100 g, and most preferably from 6 g/100 g to 12 g/100 g, at 35°C.

12. A process according to any preceding clause, wherein the one or more fats have an iodine value of: from 30 to 70, preferably from 40 to 60, from 50 to 60, particularly from 52 to 60, and most preferably about 56.

13. A process according to any preceding clause, wherein the one or more fats comprise: from 30 g/100 g to 70 g/100 g saturated fatty acids, preferably from 40 g/100 g to 60 g/100 g, from 40 g/100 g to 50 g/100 g, from 40 g/100 g to 45 g/100 g, saturated fatty acids, and most preferably about 43 g/100 g of saturated fatty acids.

14. A process according to any preceding clause, wherein the one or more fats comprise less than 2 g/100 g trans fats, and preferably less than 1 g/100 g trans fats.

15. A process according to any preceding clause, wherein the one or more fats are interesterified.

16. A process according to any preceding clause, wherein the one or more fats consist of palm oil.

17. A process according to any preceding clause, wherein the mixture comprises wafer rework.

18. A process according to the previous clause, wherein the mixture comprises wafer rework in an amount from 3 wt.% to 20 wt.%, preferably in an amount from 5 wt.% to 15 wt.%.

19. A process according to any preceding clause, wherein the mixture comprises cocoa powder.

20. A process according to any preceding clause, wherein the mixture is substantially free of water.

21 . A process according to any preceding clause, wherein the mixture comprises from 30 wt.% to 65 wt.%, preferably 40 wt.% to 60 wt.%, most preferably 45 wt.% to 60 wt.% of one or more sweeteners. 22. A process according to any preceding clause, wherein the one or more added sweeteners comprise saccharides (preferably chosen from sucrose, glucose, galactose, lactose, maltose, fructose, corn syrup, and polydextrose), and/or polyols (preferably chosen from sorbitol, mannitol, maltitol, isomalt, xylitol or erythritol).

22. A process according to any preceding clause, wherein the one or more added sweeteners comprise monosaccharides and disaccharides, preferably chosen from sucrose, glucose, galactose, lactose, maltose, and fructose, most preferably sucrose.

23. A process according to any preceding clause, wherein the one or more added sweeteners consist of sucrose.

24. A process according to any preceding clause, wherein stirring and cooling the heated mixture takes place at a shear rate of from 1 s’¹ to 200 s’¹, preferably 1 s’¹ to 100 s’¹, and most preferably 1 s’¹ to 50 s’¹.

25. A process according to any preceding clause, wherein the mixture is heated to a temperature of: from 60°C to 70°C, preferably from 63°C to 68°C, and more preferably about 65°C.

26. A process according to any preceding clause, wherein the cooling rate is less than 5.0°C per minute, preferably less than 4°C per minute, and most preferably less than 3°C per minute; or wherein the cooling rate is: from 0.5°C per minute to 4.5°C per minute, preferably from 1 °C per minute to 3.5°C per minute, more preferably from 1 °C per minute to 3°C per minute, or from 1 °C per minute to 2.5°C per minute, or from 1 °C per minute to 2 °C per minute.

27. A process according to any preceding clause, wherein the cooling rate is about 1.0°C per minute.

28. A process according to any preceding clause wherein the shear rate is: from 1 s’¹ to 20 s’¹, preferably from 1 s’¹ to 10 s’¹, and most preferably about 5 s’¹.

29. A process according to any preceding clause wherein the heated mixture is cooled in a first heat exchanger to an intermediate temperature, following by being further cooled in a second heat exchanger to the layering temperature.

30. A process according to the previous clause wherein the intermediate temperature is: from 40°C to 60°C, preferably from 45°C to 55°C, and most preferably about 50°C.

31. A process according to any preceding clause wherein the cooled mixture has a viscosity of: 6000 cP to 15000 cP, and preferably 9000 cP to 11000 cP. 32. A process according to any preceding clause wherein the cooled mixture has a viscosity of about 10000 cP.

33. A process according to any preceding clause wherein the heated mixture is cooled to a temperature of: from 30°C to 40°C, preferably from 32°C to 38°C, and most preferably from 34°C to 36°C.

34. A process according to any preceding clause wherein the heated mixture is cooled to a temperature of about 35°C.

35. A process according to any preceding clause wherein the filling cream layer(s) has a thickness of: from 3.8 mm to 4.5 mm, preferably from 3.9 mm to 4.5 mm, and more preferably from 4.0 to 4.5 mm.

36. A process according to any preceding clause wherein the filling cream layer(s) have a thickness of from 4.0 to 4.2 mm, preferably about 4.0 mm.

37. A process according to any preceding clause wherein the confectionery product consists of a filling cream layer sandwiched between two wafer layers.

38. A process according to any preceding clause wherein step (g) comprises enrobing the cut edible substrate in chocolate.

39. A confectionery product produced by a process according to any preceding clause.

40. A book-cut confectionery product comprising two or more edible substrate layers and one or more filling cream layers in between the edible substrate layers, wherein: the one or more filling cream layers comprise one or more added fats, one or more sugars, and optionally one or more flavourings; the one or more filling cream layers have a thickness of greater than 3.5 mm, wherein the one or more filling cream layers are as defined in any of clauses 6 to 23.

41. A confectionery product according to clause 40, wherein the one or more edible substrate layers is a baked foodstuff, preferably a wafer sheet.

42. A confectionery product according to clause 40 or clause 41 , wherein one or more of the filing cream layers has a thickness of: from 3.8 mm to 4.5 mm, preferably from 3.9 mm to 4.5 mm, and more preferably from 4.0 to 4.5 mm. 43. A confectionery product according to any of clauses 40, 41 or 42, wherein one or more of the filling cream layers has a thickness of from 4.0 to 4.2 mm, preferably about 4.0 mm.

44. A confectionery product according to any of clauses 40, 41 or 42, wherein the confectionery product consists of a filling cream layer sandwiched between two wafer layers. 45. A confectionery product according to any of clauses 40, 41 or 42, wherein the confectionery product comprises a filling cream layer as defined in any of clauses 6 to 23, sandwiched between two wafer layers, preferably wherein the confectionery product is chocolate coated.

Claims

1 . A process of preparing a confectionery product comprising a filling cream layer, the process comprising:

(c) stirring and cooling the heated mixture to a temperature of: from 20°C to 45°C at a cooling rate of less than 5°C per minute and at a shear rate of from 1 s^-1 to 250 s’¹, to provide a cooled filling cream mixture having a viscosity of at least 6000 cP; and;

(f) cutting the book to from a plurality of cut products, and optionally processing the cut product to form a confectionery product.

2. A process according to claim 1 , wherein step (e) further comprises:

(i) applying the cooled filling cream mixture to the second edible substrate to form a second filling cream layer, and

(ii) placing a third edible substrate, on the second filling cream layer to form a multilayer book; and

(iii) optionally repeating (e-i) and (e-ii).

3. A process according to claim 1 or claim 2, wherein the edible substrate is a baked foodstuffs, preferably a wafer sheet.

4. A process according to any preceding claim, wherein the mixture has a total fat content of from 20 wt.% to 45 wt.%, preferably from 30 wt.% to 35 wt.%, and most preferably about 33 wt.%.

5. A process according to any preceding claim, wherein the mixture comprises from 15 wt.% to 40 wt.%, preferably from 25 wt.% to 35 wt.%, most preferably from 28 wt.% to 32 wt.% of the one or more added fats.

6. A process according to any preceding claim, wherein the one or more added fats have a solid fat content of: from 15 g/100 g to 60 g/100 g, preferably from 20 g/100 g to 50 g/100 g, and most preferably from 25 g/100 g to 35 g/100 g, at 20°C.

7. A process according to any preceding claim, wherein the one or more added fats have a solid fat content of: from 10 g/100 g to 50 g/100 g, preferably from 15 g/100 g to 40 g/100 g, and most preferably from 16 g/100 g to 26 g/100 g, at 25°C.

8. A process according to any preceding claim, wherein the one or more added fats have a solid fat content of: from 5 g/100 g to 30 g/100 g, preferably from 10 g/100 g to 25 g/100 g, and most preferably from 10 g/100 g to 18 g/100 g, at 30°C.

9. A process according to any preceding claim, wherein the one or more added fats have a solid fat content of: from 2 g/100 g to 20 g/100 g, preferably from 4 g/100 g to 15 g/100 g, and most preferably from 6 g/100 g to 12 g/100 g, at 35°C.

10. A process according to any preceding claim, wherein the mixture comprises: from 30 wt.% to 65 wt.%, preferably 40 wt.% to 60 wt.%, most preferably 45 wt.% to 60 wt.% of one or more added sweeteners.

11. A process according to any preceding claim, wherein the one or more added sweeteners comprise saccharides, preferably chosen from: sucrose, glucose, galactose, lactose, maltose, fructose, corn syrup, and polydextrose), and/or polyols (preferably chosen from sorbitol, mannitol, maltitol, isomalt, xylitol or erythritol).

12. A process according to any preceding claim, wherein the one or more added sweeteners comprise monosaccharides and/or disaccharides, preferably chosen from sucrose, glucose, galactose, lactose, maltose, and fructose, most preferably sucrose.

13. A process according to any preceding claim, wherein the one or more added sweeteners comprises of, consists of, or consists essentially of sucrose.

14. A process according to any preceding claim, wherein stirring and cooling the heated mixture takes place at a shear rate of: from 1 s^-1 to 200 s’¹, preferably 1 s^-1 to 100 s’¹, and most preferably 1 s^-1 to 50 s’¹.

15. A confectionery product produced by a process according to any preceding claim.

16. A book-cut confectionery product comprising two or more edible substrate layers and one or more filling cream layers in between the edible substrate layers, wherein: the one or more filling cream layers comprise one or more added fats, one or more sugars, and optionally one or more flavourings; the one or more filling cream layers have a thickness of at least 3.5 mm, wherein the one or more filling cream layers are as defined in any of claims 4 to 13, and/or the edible substrate layers is a baked foodstuff, preferably a wafer sheet.

17. A confectionery product according to claim 16, wherein the confectionery product comprises a filling cream layer as defined in any of clauses 6 to 23, sandwiched between two wafer layers, preferably which is chocolate-coated.