Science and Technology of Enrobed and Filled Chocolate, Confectionery and Bakery Products

Cover Page......Page 1
Title Page......Page 2
ISBN 978-1845693909......Page 3
Table of Contents......Page 4
Contributor Contact Details......Page 10
1.1 Introduction......Page 13
1.2 Enrobed and Filled Products......Page 15
1.2.1 Definitions......Page 16
1.2.2 Market Trends......Page 17
1.3 Scope of the Book......Page 18
References......Page 19
2.1 Introduction......Page 23
2.2.1 Cocoa Based......Page 24
2.2.2 Sugar......Page 26
2.2.4 Emulsifiers......Page 27
2.4.1 Importance of Particle Size......Page 28
2.4.2 Two- and Five-Roll Refining......Page 29
2.4.3 Dry Grinding......Page 31
2.4.4 Batch Systems......Page 32
2.5.1 Flavour Changes......Page 33
2.5.2 Liquefying......Page 35
2.5.3 The Conche......Page 37
2.6.2 Sensory Properties......Page 38
2.7 Future Trends......Page 39
References......Page 40
3.1 Introduction......Page 41
3.2.1 European Union......Page 42
3.2.2 United States of America......Page 45
3.3.1 Cocoa......Page 46
3.3.2 Sugar......Page 48
3.3.3 Milk......Page 49
3.3.4 Emulsifiers......Page 51
3.4 Formulations for Industry Sectors......Page 52
3.4.1 Bakery Applications......Page 53
3.4.2 Confectionery......Page 54
3.4.3 Ice Cream......Page 55
3.4.4 Inclusions......Page 56
3.5.1 Origin Chocolate......Page 57
3.5.2 Organic Products......Page 58
3.5.3 Fairtrade......Page 59
3.5.4 Without Added Sugar......Page 60
3.6 Health Aspects......Page 61
3.6.3 Probiotic......Page 62
3.7 Future Trends......Page 63
References......Page 64
4.1 Introduction......Page 65
4.1.1 Fats and Fatty Acids......Page 66
4.2 Crystal Structure and Polymorphism of Fats......Page 69
4.3.1 Cocoa Butter and Cocoa Butter Equivalents (CBE)......Page 73
4.3.3 Non-Lauric Cocoa Butter Replacers......Page 80
4.4.1 Effects on Recipe......Page 81
4.4.3 Effects on Quality......Page 82
4.5.1 Coatings......Page 83
4.5.2 Fillings......Page 84
4.6 Trans Fats......Page 85
4.6.2 Effect on Saturates Level......Page 86
4.7 Future Trends......Page 88
References......Page 90
5.1 Introduction......Page 92
5.2.2 Non-Lauric Cocoa Butter Replacers......Page 94
5.2.4 Formulation Constraints......Page 96
5.3 Recipes......Page 99
5.4 Flavourings and Colourings......Page 101
5.5.1 Effect on Melting Profile and Meltdown in the Mouth......Page 102
5.5.2 Effect on Shelf Life and Risk of Fat Bloom......Page 104
5.6.2 Tempering......Page 105
5.6.4 Cooling......Page 106
5.6.6 Specific Problems Associated with Lauric Cocoa Butter Substitute Coatings......Page 108
5.7 Future Trends......Page 110
References......Page 111
6.1 Introduction......Page 113
6.2.1 Fats......Page 114
6.2.2 Fat Replacers......Page 118
6.2.3 Sugars......Page 119
6.2.4 Sugar Replacers......Page 120
6.2.6 Milk Powders and Milk Powder Replacers......Page 121
6.2.7 Nuts......Page 122
6.2.8 Colours......Page 123
6.3 Recipes......Page 124
6.3.2 Nougats......Page 125
6.3.3 Spreads......Page 127
6.4.2 Aeration......Page 128
6.4.3 Precrystallisation......Page 129
6.4.6 One-Shot Depositors......Page 130
6.5.1 Fat Migration......Page 131
6.5.3 Rework Incorporation......Page 132
References......Page 133
7.1 Introduction......Page 135
7.2.1 Biological Stability......Page 136
7.2.3 Crystallisation......Page 137
7.2.4 Gelling......Page 138
7.3.1 Sugars......Page 139
7.3.2 Dairy Ingredients......Page 141
7.3.3 Emulsifiers......Page 143
7.3.5 Colours......Page 146
7.3.6 Gums and Gelling Agents......Page 147
7.4 Processing......Page 150
7.4.2 Shaping......Page 152
7.4.3 Depositing......Page 153
7.5.2 Caramels and Toffees......Page 154
7.5.3 Grained Products......Page 155
7.6 Gelled Products......Page 159
7.7.1 Organic Products......Page 161
7.8 Conclusions......Page 162
References......Page 163
8.1 Introduction......Page 164
8.2 Chocolate Formulation......Page 165
8.4 Moisture Barriers for Caramel- and Jam-Containing Biscuits......Page 167
8.5 Non-Hydrogenated Coatings......Page 168
8.6.1 Full Coated Products......Page 169
8.6.3 Biscuit and Cake Crumb-Causing Problems......Page 170
8.7.1 Legislative Quality Issues......Page 171
8.7.3 Bloom, Thermal Cracking and Moisture Migration......Page 172
8.8 Fillings for Bakery Products......Page 173
8.9 Future Trends in Chocolate Enrobing......Page 174
9.1 Introduction......Page 175
9.2.1 Ice Cream......Page 176
9.2.2 Chocolate......Page 178
9.2.3 Chocolate and Couvertures......Page 179
9.2.4 Differences between Ambient Chocolate and Chocolate for Ice Cream......Page 180
9.2.6 Challenges in Processing Ice Cream and Chocolate Together......Page 181
9.2.7 Examples of Requirements for These Properties in Ice Cream......Page 182
9.3.1 Dipping......Page 183
9.3.2 Enrobing......Page 186
9.3.3 Spraying......Page 187
9.3.5 Chocolate Aeration......Page 189
9.4 Inclusions in Ice Cream......Page 190
9.5 Future Trends......Page 192
References......Page 194
10.1 Introduction......Page 197
10.2.1 Oil Migration......Page 198
10.2.2 Fat Bloom......Page 202
10.3.1 Oil Migration......Page 207
10.3.2 Fat Bloom......Page 214
10.4.3 Cooling and Solidification......Page 216
10.4.5 Strategies for Oil Migration......Page 217
10.5 Future Trends......Page 218
References......Page 219
11.1 Introduction......Page 223
11.2.1 Diffusion Mechanisms......Page 224
11.3 Measurement of Permeability......Page 226
11.4 Reducing Moisture Migration......Page 228
11.4.1 Fat Barriers......Page 229
11.4.2 Wax-Based Barriers......Page 236
11.4.4 Carbohydrate Barriers......Page 239
11.4.6 Balancing Water Activities......Page 240
11.5.2 Minimisation of Alcohol Migration......Page 241
References......Page 243
12.1 Introduction......Page 245
12.2 Shelf-Life Testing Methods......Page 246
12.2.1 Shelf-Life Limiting Factors......Page 248
12.2.2 Sensory Test Methods......Page 249
12.2.3 Other Methods for Measuring Physical and Chemical Changes......Page 252
12.3 Sensory Changes during Storage of Chocolate Confectionery......Page 255
12.3.1 Flavour Changes......Page 257
12.3.2 Texture Deterioration of Chocolate, Wafer, Biscuit and Praline......Page 259
12.3.3 Visual Changes......Page 260
12.4 Shelf-Life Prediction......Page 261
12.4.2 Testing Regimes......Page 262
12.5 Future Trends......Page 263
References......Page 265
13.1 Introduction......Page 267
13.2 Defining Rheological Terms......Page 268
13.3.1 Measurement of Chocolate and Fat-Based Fillings......Page 271
13.4 Typical Chocolate Flow Curves......Page 274
13.5.1 Effect of Chocolate Conching......Page 277
13.5.2 Effect of Fat Content......Page 278
13.5.3 Effect of Emulsifier Choice and Dosage......Page 280
13.5.4 Effect of Particle Size......Page 281
13.5.5 Effect of Moisture Content......Page 282
13.5.6 Effect of Temperature on Viscosity......Page 283
13.5.7 Effect of Tempering on Chocolate Viscosity......Page 284
13.6.1 Caramel Structure and Rheology......Page 285
13.6.2 Structure and Rheology of Cremes and Fondants......Page 287
13.6.3 Structure and Rheology of Truffles and Pralines......Page 289
13.7 Issues with Shell Moulding......Page 290
13.8 Issues with Enrobing......Page 292
13.9 Issues with One-Shot Depositing......Page 293
13.10 Dealing with Viscoelasticity......Page 294
References......Page 295
14.1 Introduction......Page 297
14.2 Microscopy Techniques and Their Uses......Page 298
14.2.1 Light Microscopy......Page 299
14.2.2 Confocal Scanning Laser Microscopy (CSLM)......Page 303
14.2.3 Electron Microscopy......Page 305
14.3.1 Stability......Page 310
14.3.2 Heat Resistance......Page 313
14.3.3 Gloss......Page 317
References......Page 319
15.1 Introduction......Page 325
15.2 Effects of Tempering on Quality......Page 326
15.3 Polymorphism and Phase Behaviour of Triacylglycerols......Page 327
15.4 Cocoa Butter Polymorphism......Page 334
15.5 Changes during Tempering......Page 336
15.6 Factors Affecting Tempering......Page 342
15.7 Measurement of Temper......Page 345
15.8 Future Trends......Page 349
References......Page 351
16.2 Characteristics of Cocoa Butter......Page 356
16.3 Chocolate Tempering......Page 358
16.3.2 Typical Chocolate Process Flow Schemes......Page 360
16.3.3 Tempering by Seeding......Page 363
16.3.5 Measuring the Degree of Temper......Page 364
16.4 Chocolate Coating......Page 367
16.4.1 Outboard Enrober......Page 369
16.4.2 Inboard Enrober......Page 370
16.6 Aerated Chocolate......Page 371
References......Page 373
17.1 Introduction......Page 374
17.2.1 Full Coating Enrobers......Page 375
17.2.2 Half-Coating Enrobers......Page 385
17.2.3 Pre-Bottoming Enrobers......Page 387
17.3 Centre Preparation and Presentation to the Enrober......Page 388
17.4 Chocolate Application Case Study......Page 389
17.5 Chocolate Handling Systems within the Enrober......Page 391
17.5.1 Out-Board Tempering......Page 393
17.5.2 Inboard Tempering......Page 394
17.5.3 The Drain Tray......Page 395
17.5.4 Compounds Not Requiring Tempering......Page 396
17.6.2 Air Conditions in the Enrober Room......Page 397
17.6.3 Hygiene......Page 398
17.6.5 Wire Belt Life......Page 399
17.7.1 Decorating Devices......Page 400
17.7.3 Shoulder Dipping Attachment......Page 401
17.9.1 Chocolate Has Lost Temper and is Dull or Soft on the Coated Product after Cooling......Page 402
17.9.2 Chocolate Pick-up is Overweight......Page 403
17.9.5 Poor Quality Bottom Coverage after Transfer to the Cooler Belt......Page 404
17.10.4 Energy Saving......Page 406
17.10.8 Machine Size......Page 407
Acknowledgements......Page 408
18.1 Introduction......Page 409
18.2.1 Centres......Page 410
18.3.1 Means of Precoating, Stabilization, Isolation of Centres......Page 412
18.3.2 Precoating Solution......Page 413
18.3.4 Advantages and Disadvantages of Precoating......Page 414
18.4.1 Chocolate Panning......Page 415
18.4.2 Compound Panning......Page 416
18.5 Finishing......Page 417
18.6 Equipment......Page 418
18.6.2 Equipment for Chocolate Panning......Page 419
18.6.4 Equipment for Polishing......Page 423
18.7 Future Trends......Page 424
19. Manufacturing Processes: Production of Chocolate Shells......Page 426
19.1.2 Cold Stamping......Page 427
19.2 Cold Stamping Technology......Page 428
19.2.2 Cold Stamping Procedures with Moulds......Page 429
19.3 Depositing, Vibrating, Cooling and Demoulding......Page 430
19.4 Process Conditions and Product Quality......Page 434
19.6 Future Trends......Page 435
References......Page 438
20. Manufacturing Processes: Deposition of Fillings......Page 439
20.2.1 Depositor......Page 440
20.2.3 Cooling......Page 444
20.2.4 Shell and Filling Masses......Page 445
20.2.5 Product Quality......Page 446
20.3 Faults, Causes and Solutions......Page 448
20.4 Future Trends......Page 450
References......Page 451
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