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

505 Pages·2009·8.63 MB·English

by  G. Talbot

Science and technology
of enrobed and filled
chocolate, confectionery
and bakery products
Edited by
Geoff Talbot
CRC Press
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First published 2009, Woodhead Publishing Limited and CRC Press LLC
© 2009, Woodhead Publishing Limited
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Contents
Contributor contact details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
G. Talbot, The Fat Consultant, UK
1.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Enrobed and filled products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Scope of the book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Acknowledgements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Part I Formulation
2 Chocolate manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
S. Beckett, formerly of Nestlé Product Technology Centre, UK
2.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2 Raw materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Basic recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.4 Grinding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5 Conching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6 Quality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.8 Sources of further information and advice . . . . . . . . . . . . . . . . . . 27
2.9 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3 Formulation of chocolate for industrial applications . . . . . . . . . . . . . 29
P. Yates, Barry Callebaut (UK) Ltd, UK
3.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 Legislation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.3 Ingredients. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
vi Contents
3.4 Formulations for industry sectors . . . . . . . . . . . . . . . . . . . . . . . . . 40
3.5 Speciality products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.6 Health aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.7 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.8 Sources of further information and advice . . . . . . . . . . . . . . . . . . 52
3.9 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4 Fats for confectionery coatings and fillings . . . . . . . . . . . . . . . . . . . . . 53
G. Talbot, The Fat Consultant, UK
4.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.2 Crystal structure and polymorphism of fats . . . . . . . . . . . . . . . . . 57
4.3 Range of coating and filling fats. . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.4 Effects of fat on quality and processing . . . . . . . . . . . . . . . . . . . . 69
4.5 Selecting the correct fat for application type . . . . . . . . . . . . . . . . 71
4.6 Trans fats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.7 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
4.8 Sources of further information and advice . . . . . . . . . . . . . . . . . . 78
4.9 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
5 Compound coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
G. Talbot, The Fat Consultant, UK
5.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
5.2 Cocoa butter alternatives in compound coatings . . . . . . . . . . . . . 82
5.3 Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.4 Flavourings and colourings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.5 Effects of formulation on sensory and functional properties . . . . 90
5.6 Effect of fat choice on manufacturing process . . . . . . . . . . . . . . . 93
5.7 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
5.8 Sources of further information and advice . . . . . . . . . . . . . . . . . . 99
5.9 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6 Fat-based centres and fillings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
J. Birkett, AarhusKarlshamn Denmark A/S, Denmark
6.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.2 Effects of ingredients on quality . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.3 Recipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.4 Manufacturing processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
6.5 Stability and shelf-life issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.6 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.7 Sources of further information and advice . . . . . . . . . . . . . . . . . 121
6.8 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
7 Caramels, fondants and jellies as centres and fillings . . . . . . . . . . . . 123
W. P. (Bill) Edwards, Bardfield Consultants, UK
7.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.2 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Contents vii
7.3 Ingredients. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
7.4 Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.5 Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.6 Gelled products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.7 The future . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.8 Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.9 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
8 Biscuits and bakery products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
M. Brown, Burtons Foods Ltd, UK
8.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
8.2 Chocolate formulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
8.3 Emulsifiers in chocolate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
8.4 Moisture barriers for caramel- and jam-containing biscuits . . . . 155
8.5 Non-hydrogenated coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
8.6 Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
8.7 Quality issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
8.8 Fillings for bakery products . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.9 Future trends in chocolate enrobing . . . . . . . . . . . . . . . . . . . . . . 162
8.10 Sources of further information and advice . . . . . . . . . . . . . . . . . 162
9 Chocolate and couvertures: applications in ice cream . . . . . . . . . . . 163
D. J. Cebula and A. Hoddle, Unilever R&D, UK
9.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
9.2 Features of ice cream and chocolate . . . . . . . . . . . . . . . . . . . . . . 164
9.3 Application processes, formats, requirements, defects. . . . . . . . 171
9.4 Inclusions in ice cream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
9.5 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
9.6 Sources of further information and advice . . . . . . . . . . . . . . . . . 181
9.7 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Part II Product design
10 Product design and shelf-life issues: oil migration and fat bloom . . 185
G. Ziegler, Penn State University, USA
10.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
10.2 Mechanisms of oil migration and fat bloom . . . . . . . . . . . . . . . . 186
10.3 Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
10.4 Optimizing product quality in relation to oil migration
and fat bloom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
10.5 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10.6 Sources of further information . . . . . . . . . . . . . . . . . . . . . . . . . . 206
10.7 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
viii Contents
11 Product design and shelf-life issues: moisture and ethanol
migration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
G. Talbot, The Fat Consultant, UK
11.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
11.2 Mechanism of moisture migration . . . . . . . . . . . . . . . . . . . . . . . 212
11.3 Measurement of permeability . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
11.4 Reducing moisture migration . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
11.5 Alcohol (ethanol) migration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
11.6 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
11.7 Sources of further information and advice . . . . . . . . . . . . . . . . . 231
11.8 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
12 Shelf-life prediction and testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
P. J. Subramaniam, Leatherhead Food International, UK
12.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
12.2 Shelf-life testing methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
12.3 Sensory changes during storage of chocolate confectionery . . . 243
12.4 Shelf-life prediction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
12.5 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
12.6 Sources of further information and advice . . . . . . . . . . . . . . . . . 252
12.7 Acknowledgements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
12.8 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
13 Controlling the rheology of chocolate and fillings . . . . . . . . . . . . . . . 255
M. Wells, formerly of Cadbury Trebor Bassett, UK
13.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
13.2 Defining rheological terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256
13.3 How to measure the rheology of chocolate and fillings . . . . . . . 259
13.4 Typical chocolate flow curves. . . . . . . . . . . . . . . . . . . . . . . . . . . 263
13.5 Factors affecting chocolate rheology . . . . . . . . . . . . . . . . . . . . . 265
13.6 The rheology of fillings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
13.7 Issues with shell moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
13.8 Issues with enrobing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
13.9 Issues with one-shot depositing. . . . . . . . . . . . . . . . . . . . . . . . . . 281
13.10 Dealing with viscoelasticity . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
13.11 Sources of further information and advice . . . . . . . . . . . . . . . . . 282
13.12 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
14 Using microscopy to understand the properties of confectionery
products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
K. Groves, Leatherhead Food International, UK
14.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
14.2 Microscopy techniques and their uses. . . . . . . . . . . . . . . . . . . . . 286
14.3 Relationships between the microstructure of chocolate and
Contents ix
coatings and their properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
14.4 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
14.5 Acknowledgement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
14.6 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Part III Processing, packaging and storage
15 Ingredient preparation: the science of tempering . . . . . . . . . . . . . . . 313
K. Smith, Unilever R&D, UK
15.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
15.2 Effects of tempering on quality. . . . . . . . . . . . . . . . . . . . . . . . . . 314
15.3 Polymorphism and phase behaviour of triacylglycerols. . . . . . . 315
15.4 Cocoa butter polymorphism . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
15.5 Changes during tempering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
15.6 Factors affecting tempering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
15.7 Measurement of temper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
15.8 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
15.9 Sources of further information and advice . . . . . . . . . . . . . . . . . 338
15.10 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
16 Tempering process technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
K. Richter, Sollich KG, Germany
16.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
16.2 Characteristics of cocoa butter . . . . . . . . . . . . . . . . . . . . . . . . . . 344
16.3 Chocolate tempering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
16.4 Chocolate coating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
16.5 Chocolate moulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
16.6 Aerated chocolate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
16.7 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
16.8 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
17 Manufacturing processes: enrobing . . . . . . . . . . . . . . . . . . . . . . . . . . 362
M. J. Bean, Baker Perkins Ltd, UK
17.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
17.2 Types of enrobing machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
17.3 Centre preparation and presentation to the enrober . . . . . . . . . . 376
17.4 Chocolate application case study . . . . . . . . . . . . . . . . . . . . . . . . 377
17.5 Chocolate handling systems within the enrober . . . . . . . . . . . . . 379
17.6 Environmental and hygiene issues . . . . . . . . . . . . . . . . . . . . . . . 385
17.7 Ancillary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
17.8 Typical operating parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
17.9 Faults and remedies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
17.10 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
17.11 Sources of further information and advice . . . . . . . . . . . . . . . . . 396
x Contents
17.12 Acknowledgements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
18 Manufacturing processes: chocolate panning and inclusions . . . . . 397
G. Geschwindner and H. Drouven, Drouven & Fabry GmbH, Germany
18.1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
18.2 Centres and raw materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
18.3 Preparation of the centres: precoating. . . . . . . . . . . . . . . . . . . . . 400
18.4 Panning process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
18.5 Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
18.6 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
18.7 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412
18.8 Sources of further information and advice . . . . . . . . . . . . . . . . . 412
19 Manufacturing processes: production of chocolate shells . . . . . . . . 414
J. Meyer, Bühler Bindler GmbH, Germany
19.1 Fundamentals of chocolate shell production methods . . . . . . . . 415
19.2 Cold stamping technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
19.3 Depositing, vibrating, cooling and demoulding . . . . . . . . . . . . . 418
19.4 Process conditions and product quality. . . . . . . . . . . . . . . . . . . . 422
19.5 Faults, causes and solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
19.6 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
19.7 Sources of further information and advice . . . . . . . . . . . . . . . . . 425
19.8 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
20 Manufacturing processes: deposition of fillings . . . . . . . . . . . . . . . . 427
J. Meyer, Bühler Bindler GmbH, Germany
20.1 Modern processes for depositing fillings into premade
shells: One-Shot technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
20.2 One-Shot process conditions and product quality. . . . . . . . . . . . 428
20.3 Faults, causes and solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436
20.4 Future trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
20.5 Sources of further information and advice . . . . . . . . . . . . . . . . . 438
20.6 References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Contributor contact details
(* = main contact)
Chapters 1, 4, 5, 11 Wildmere Road
Banbury
Geoff Talbot
OX16 3UU
The Fat Consultant
UK
Suite 250
Email: Phil_Yates@barry-
St Loyes House
callebaut.com
20 St Loyes Street
Bedford
MK40 1ZL
UK Chapter 6
Email: [email protected]
J. Birkett
AarhusKarlshamn Denmark A/S
DK-8000 Aarhus C
Chapter 2 Denmark
Dr S. T. Beckett Email: [email protected]
Formerly of Nestlé Product
Technology Centre
Haxby Road
Chapter 7
York
YO91 1XY Dr Bill Edwards
UK Bardfield Consultants
14 Durham Close
Email: [email protected]
Gt. Bardfield
Braintree
Essex
Chapter 3 CM7 4UA
UK
Philip Yates
UK Product Manager Email: BillEdwards@bardfield
Barry Callebaut (UK) Ltd consultants.co.uk