Table Of ContentScience and technology
of enrobed and filled
chocolate, confectionery
and bakery products
Edited by
Geoff Talbot
CRC Press
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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
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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
