CONFECTIONERY PRODUCT

FIELD OF THE INVENTION

The present invention relates to a confectionery product comprising a moulded first layer and a moulded second layer. In particular, the present invention relates to a process for the preparation such a confectionery product.

BACKGROUND OF THE INVENTION

Many chocolate articles are shaped as part of a moulding operation. This includes depositing liquid tempered chocolate masses into a mould, cooling and demoulding to impart a defined shape to the finished article. For demoulding to work efficiently the chocolate mass has to solidify and contract sufficiently to release from the mould cavity. For chocolate masses, this is aided to a large part by fat crystallization and to a lesser extent by thermal contraction.

Chocolate confectionery products often include fillings, which tend to have a softer texture than chocolate. These fillings also use fats that generally do not require tempering and are cheaper than cocoa butter. These fillings do not demould due to their crystallization and texture characteristics. To enable demoulding of filled confectionery articles, the filling is always in direct contact and surrounded by chocolate. This chocolate coating provides an additional level of protection to the more heat and compression sensitive filling throughout the supply chain and during consumption.

There are chocolate like compounds that are similar in taste and texture to chocolate, but do not meet chocolate regulatory requirements due to their composition. These are often based on cocoa butter equivalent or cocoa butter replacers. While being mouldable, they do not provide the same sensory experience of a soft filling.

In terms of visible fillings, there have been commercially available confectionery products where the back (or bottom) of the product which is not in contact with the mould is left uncovered, but this results in an undefined shape of the filling on the “wrong” side of the product. This leads to an inferior and incomplete visual experience. As the filling is not shaped by the mould it would not be considered a moulded confectionery filling. Such fillings are described as an embodiment of EP2804487.

Alternatively, it is possible to fill chocolate cavities after demoulding with fillings or inclusions on the top of the product. Nonetheless, this would require additional depositing and cooling steps after demoulding and before packing, which in most cases makes it cost prohibitive. In this case, the filling shape will be limited to the flow properties of the filling, depositing technique and subsequent handling, versus taking on the shape of the mould.

The combination of softer texture, poor contraction and demoulding requirements are challenging and there are no known examples of moulded visible soft layers. The present invention provides a means of providing a product that contains the unique product features to achieve such confectionery products. This invention uses a combination of features to enable the demoulding of soft visible layers within common cooling conditions and cycle times without significant equipment modifications on moulding plants that produce filled confectionery articles.

Additionally, it is well known to produce confectionery products with multiple layers, specifically chocolate tablets with at least two layers of chocolate and/or compound. However, both layers have the same texture and are “hard” and generally brittle.

To summarise, the concept of moulded soft at least bi-layer confectionery, preferably chocolate, products is new, particularly the soft first layer formulation, order of dosing first layer and second layer, preferably chocolate, into a mould, the combination of features to aid demoulding of the confectionery products, as well as a means of protecting the softer first layer in its exposed form.

Hence, this invention solves the following issues: poor contraction and demoulding of soft first layer, poor product presentation of tablets with differing textures, while providing defined moulded shapes to soft first layers, providing protection for soft first layers, avoiding significant equipment modification on moulding plants making filled confectionery products and developing shelf stable fat based first layers.

SUMMARY OF THE INVENTION

According to a first aspect of the invention, provided is a confectionery product comprising at least two layers, wherein said two layers are both moulded, the process comprising:

(a) depositing the first layer in a mould;

(b) depositing a second layer in the mould on top of the first layer;

(c) optional further component addition;

(d) cooling; and (e) demoulding, wherein both layers have portions directly in contact with the mould until the demoulding step, wherein the first layer post-demoulding has a hardness of between 1.90 N and 20.0 N at 20°C.

The invention further provides a confectionery product comprising a second layer and a first layer, wherein the first layer is moulded and visible and first layer has a hardness of between 1.90 N and 20.0 N at 20°C.

DETAILED DESCRIPTION OF THE INVENTION

Definitions

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

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 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.

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.

First layer

According to any embodiment of the present invention, the first layer preferably comprises one or more added fats, one or more non-fat solids, and optionally one or more flavourings, colourants and/or emulsifiers. These components will be discussed below.

The first layer, preferably measured post-demoulding, preferably has a hardness of between 1.90 N and 20.0 N at 20°C, preferably between 1.95 N and 18. N, preferably between 1.95 N and 15.0 N, preferably between 1.95 N and 10.0 N, preferably between 2.0 N and 8.0 N and most preferably between 2.25 and 6.0 N. The hardness is measured using the method of the examples set out below. It is noted that a depth of 8mm is used in this method. In the interests of clarity, this does not mean that all first layers of the present invention have to be at least 8mm deep. Rather, this means when assessing the hardness of a first layer it is carried out on a sample that is greater than 8mm deep.

The hardness of the first layer is predominantly controlled by the fat content and distribution of fats within the first layer at a specific temperature. These features are discussed in more detail below.

As mentioned above, thermal contraction of the first layer may impact the demoulding. The first layers within the scope of the present invention display contraction degrees that assist demoulding without impacting texture or appearance. The contraction degree is defined as the total contraction between the largest volume and the smallest volume (i.e. including any volume growth caused by crystallisation and the subsequent contraction) given as a percentage of the starting volume (typically the starting volume will be smaller than the largest volume owing to crystallisation growth but larger than the smallest volume owing to thermal contraction).

The first layer preferably has a contraction degree of at least 0.60% when measured using a Choco-analyser (Aasted), preferably using the method set out in the examples below. Preferably, the first layer has a contraction degree of at least 0.65%, more preferably at least 0.70%, more preferably at least 0.75 and most preferably at least 0.80%.

Preferably, the first layer has a contraction degree of less than or equal to 5.0%, preferably less than or equal to 3.0%, preferably less than or equal to 2.5%, or less than or equal to 2.0%, or less than or equal to 1.5% or less than or equal to 1.0%. The upper limit is far less important than the lower limit, which controls the quality of demoulding. However, in preferred embodiments, the contraction degree is from 0.60% to 5.0%, from 0.65% to 3.0%, from 0.65% to 2.0% or from 0.70% to 1.5%.

The first layer preferably contains no added water. In a preferred embodiment, the first layer is substantially free of water. Preferably the first layer 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)/fat(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/fat" (unless the context indicates otherwise) both denote edible oils that are liquid at the stated temperature. This is defined further below.

In an embodiment, the first layer has a total fat content of from 15 wt.% to 50 wt.%, preferably from 20 wt.% to 45 wt.%, and most preferably from 25 wt.% to 40 wt.%.

In one embodiment, the first layer comprises from 15 wt.% to 50 wt.%, preferably from 20 wt.% to 45 wt.%, most preferably from 25 wt.% to 40 wt.% of the one or more added fats. It will be appreciated that the total amount of fat in the first layer 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 first layer, for example, chocolate.

The term “solid fat” has its standard definition, i.e. a fat that is solid, i.e. stable in shape, at room temperature.

The term “liquid fat” has its standard definition, i.e. a fat that is liquid, i.e. flows to take on the shape of its container, at room temperature (i.e. standard ambient temperature defined below).

In a preferred embodiment, the solid fat content (SFC) of the individual fats is measured using IIIPAC 2.150a or 2.150b at 20°C. The percentage is given as weight percentage of the measured fat content, i.e. for the first layer, not as a percentage of the whole first layer.

A liquid fat preferably has a solid fat content of less than 15% by weight, preferably less than 10% by weight, preferably less than 7.5% by weight, preferably less than 5% by weight, preferably less than 2.5% by weight and preferably less than 0.5% by weight, i.e. 0.0wt%, measured using IIIPAC 2.150a at 20°C. For example, between 0.0wt% and 15wt%.

In this regard, it is noted that solid fats within the meaning of the invention do not necessarily have an SFC of 100% measured using IIIPAC 2.150a or 2.150b at 20°C. Hence, there is a difference between the terms “solid fat content” and “solid fat”. The solid fat relates to the fat itself, which overall may be solid at room temperature, i.e. “solid fat content” (SFC) is a specific property measured according to the methods defined herein. When referring to the fats in isolation, the solid fat content relates to the content measured using IIIPAC 2.150a or 2.150b at 20°C. The solid fat content of the first layer is measured at different temperatures using the method set out below.

A solid fat within the meaning of the present invention preferably has an SFC content of between 17wt% and 100wt% or between 20wt% and 100wt% measured using IIIPAC 2.150a or 2.150b at 20°C, preferably greater than or equal to 25wt%, or greater than or equal to 30wt%. In a preferred embodiment, the solid fat within the meaning of the present invention preferably has an SFC content of less than or equal to 100wt%, less than or equal to 95wt%, less than or equal to 85wt% or less than or equal to 75wt% solid fat measured using IIIPAC 2.150a at 20°C.

In a preferred embodiment, the first layer comprises a fat with an SFC of between 20wt% and 85wt%, and preferably between 30wt% and 75wt% measured using IIIPAC 2.150a or 2.150b at 20°C.

In a preferred embodiment, the first layer comprises a fat with an SFC of between 18wt% and 80wt%, and preferably between 20wt% and 70wt% measured using IIIPAC 2.150a or 2.150b at 25°C.

In a preferred embodiment, the first layer comprises a fat with an SFC of between 10wt% and 60wt%, and preferably between 12wt% and 55wt% measured using IIIPAC 2.150a or 2.150b at 30°C.

In a preferred embodiment, the first layer comprises a fat with an SFC of between 18wt% and 80wt%, and preferably between 20wt% and 70wt% measured using IIIPAC 2.150a or 2.150b at 30°C.

SFCs measured using IIIPAC 2.150a or 2.150b may be found in the Handbook, Vegetable oils and fats, published by AAK AB, for example.

In respect of the choice of which IIIPAC method to use when assessing the SFC, we note that the person skilled in the art is aware of which method is applicable to which type of fat. In general, when a fat requires tempering, i.e. the fat composition is subjected to a thermal treatment, in particular to a cooling and heating programme which is adapted to the nature of the fat, so as to promote crystallisation of the fat in a stable crystalline form. In particular within the scope of the present invention, where the solid fat content is measured with IIIPAC method 2.150 a, the fat composition is not required to be subjected to a thermal treatment. IIIPAC method 2.150b requires the fat composition being subjected to the thermal treatment programme described in that method.

In an embodiment, the first layer of the present invention comprises a liquid fat.

In a preferred embodiment when a liquid fat is present in the first layer, the liquid fat is not the only added fat in the first layer. In a preferred embodiment, the liquid fat is present in combination with a solid fat as defined above. In an embodiment, the first layer composition comprises a solid fat and a liquid fat, wherein the weight ratio of liquid fat to solid fat is at most 1.5: 1.0, preferably at most 1.4: 1.0, more preferably at most 1.2: 1.0, more preferably at most 1.1 : 1.0, and more preferably at most 1.0: 1.0. In an embodiment, the weight ratio of liquid fat to solid fat is at least 0.01 :1.0, at least 0.05:1.0, at least 0.10:1.0 or at least 0.20:1.0. Accordingly, in a preferred embodiment, the ratio of liquid fat to solid fat is between 1.5: 1.0 and 0.01 :1.0, preferably between 1.4: 1.0 and 0.05:1.0 and preferably between 1.2: 1.0 and 0.10:1.0. For certainty, in the above ratios, a value of 1.0: 1.0, for example, equates to a 50wt% combination each of liquid fat and solid fat.

The solid fat content of the first layer is measured using IIIPAC 2.150a, preferably by the method set out in the examples. It is noted that this is the method used in EP2804487, which is set out as a comparative example below.

In an embodiment, the first layer has a solid fat content of from 50% to 90%, preferably from 60% to 85%, preferably from 65% to 85%, and most preferably from 67.5% to 80%, at 0°C.

In an embodiment, the first layer has a solid fat content of from 45% to 85%, preferably from 50% to 85%, preferably from 55% to 80%, and most preferably from 60% to 80% or from 62.5 to 75.5%, at 10°C.

In a highly preferred embodiment, the first layer has a solid fat content of from 60.0% to 85% at 0°C and a solid fat content from 55% to 85% at 10°C.

In an embodiment, the first layer has a solid fat content of from 40% to 80%, preferably from 45% to 75%, preferably from 50% to 75%, and most preferably from 55% to 70%, at 15°C.

In an embodiment, the first layer has a solid fat content of from 30% to 75%, from 35% to 70%, preferably from 40% to 65%, and most preferably from 50% to 65%, at 20°C.

In an embodiment, the first layer has a solid fat content of from 30% to 70%, preferably from 30% to 65%, preferably from 45% to 60%, and most preferably from 50% to 60%, at 25°C.

In an embodiment, the first layer has a solid fat content of from 30% to 70%, preferably from 35% to 65%, preferably from 40% to 60%, and most preferably from 42.5% to 55%, at 30°C.

In an embodiment, the first layer has a solid fat content of from 30% to 75%, preferably from 35% to 65%, preferably from 40% to 60%, and most preferably from 42.5% to 55%, at 35°C.

In a highly preferred embodiment, the first layer has a solid fat content of from 60% to 85% at 0°C, a solid fat content of from 55% to 85% at 10°C and a solid fat content of from 30% to 70% at 30°C. In a preferred embodiment, the first layer has solid fat content of 40% to 80% at 15°C, a solid fat content of 30% to 75% at 20°C and a solid fat content of 30% to 70% at 30°C.

In a preferred embodiment, the first layer has solid fat content of 45% to 75% at 15°C, a solid fat content of 35% to 70% at 20°C and a solid fat content of 35% to 65% at 30°C.

In a preferred embodiment, the first layer has solid fat content of 55% to 65% at 15°C, a solid fat content of 50% to 60% at 20°C and a solid fat content of 42.5% to 55% at 30°C.

Although it is noted that some of the above ranges overlap at different temperatures, it is inherently clear to the person skilled in the art that the solid fat content cannot be higher at a higher temperature, i.e. the SFC at a lower temperature cannot be lower than the SFC at a higher temperature.

In a preferred embodiment, the first layer has at least two of a solid fat content at 0°C as described above, a solid fat content at 10°C as described above, a solid fat content at 15°C as described above, a solid fat content at 25°C as described above, and a solid fat content at 30°C as described.

In a preferred embodiment, the first layer has a solid fat content at 0°C as described above, a solid fat content at 10°C as described above, and a solid fat content at 30°C as described.

In a preferred embodiment, the first layer has a solid fat content at 0°C as described above, a solid fat content at 10°C as described above, a solid fat content at 15°C as described above, a solid fat content at 25°C as described above, and a solid fat content at 30°C as described.

In a highly preferred embodiment, the first layer has a solid fat content at 0°C of from 50% to 90%, a solid fat content at 10°C of from 45% to 85%, a solid fat content at 15°C of from 40% to 80%, a solid fat content at 25°C of from 30% to 70%, and a solid fat content at 30°C of from 30% to 70%.

In a highly preferred embodiment, the first layer has a solid fat content at 0°C of from 60% to 85%, a solid fat content at 10°C of from 50% to 85%, a solid fat content at 15°C of from 45% to 75%, a solid fat content at 25°C of from 30% to 70%, and a solid fat content at 30°C of from 35% to 65%.

In a highly preferred embodiment, the first layer has a solid fat content at 0°C of from 67.5% to 80%, a solid fat content at 10°C of from 55% to 85%, a solid fat content at 15°C of from 55% to 70%, a solid fat content at 25°C of from 50% to 60%, and a solid fat content at 30°C of from 42.5% to 55%. In a preferred embodiment, the first layer has a solid fat content at 0°C as described above, a solid fat content at 10°C as described above, a solid fat content at 15°C as described above, a solid fat content at 20°C, a solid fat content at 25°C as described above, and a solid fat content at 30°C as described above. In a particularly preferred embodiment, the first layer has a solid fat content at 0°C as described above, a solid fat content at 10°C as described above, a solid fat content at 15°C as described above, 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.

In a preferred embodiment, the first layer has a ratio of solid fat content at 0°C to solid fat content at 30°C between 1.36 and 1.63, preferably between 1.40 and 1.62, more preferably between 1.42 and 1.60 and most preferably between 1.45 and 1.57.

In a preferred embodiment, the first layer has a ratio of solid fat content at 10°C to solid fat content at 30°C between 1.27 and 1.53, preferably between 1.28 and 1.50, more preferably between 1.30 and 1.49 and most preferably between 1.32 and 1.48.

In a preferred embodiment, the first layer has a ratio of solid fat content at 15°C to solid fat content at 30°C between 1.23 and 1.60, preferably between 1.24 and 1.50, more preferably between 1.24 and 1.45 and most preferably between 1.24 and 1.40.

In a preferred embodiment, the first layer has a ratio of solid fat content at 20°C to solid fat content at 30°C between 1.10 and 1.50, preferably between 1.11 and 1.40, more preferably between 1.11 and 1.30 and most preferably between 1.11 and 1.20.

In a preferred embodiment, the first layer has a ratio of solid fat content at 25°C to solid fat content at 30°C between 1.04 and 1.40, preferably between 1.05 and 1.30, more preferably between 1.06 and 1.20 and most preferably between 1.06 and 1.15.

In a very highly preferred embodiment, the first layer has a ratio of solid fat content at 0°C to solid fat content at 30°C between 1 .40 and 1.62 and a ratio of solid fat content at 10°C to solid fat content at 30°C between 1.28 and 1.50.

In a highly preferred embodiment, the first layer has a solid fat content of from 60% to 85% at 0°C, a solid fat content from 55% to 85% at 10°C and a solid fat content of from 30% to 70% at 30°C and the first layer has a ratio of solid fat content at 0°C to solid fat content at 30°C between 1.36 and 1.63, preferably between 1.40 and 1.62, more preferably between 1.42 and 1.60 and most preferably between 1.45 and 1.57. In a highly preferred embodiment, the first layer has a solid fat content of from 60% to 85% at 0°C, a solid fat content from 55% to 85% at 10°C and a solid fat content of from 30% to 70% at 30°C and the first layer has a ratio of solid fat content at 0°C to solid fat content at 30°C between 1.40 and 1.62 and a ratio of solid fat content at 10°C to solid fat content at 30°C between 1.28 and 1.50.

By controlling the solid fat content profile to match the above definitions it is possible to control the texture and the demoulding of the first layer to ensure the appropriate consumer experience and manufacturing ease.

The fats that are preferably used to achieve the above fat distributions are discussed below.

The liquid fat optionally used for preparing the first layer can be any vegetable oil or fat that is liquid or that can be liquefied at ambient conditions. The oil is suitably a food grade oil. Examples include sunflower oil, rapeseed oil, olive oil, soy oil, soy bean, fish oil, linseed oil, safflower oil, corn oil, algae oil, cottonseed oil, grape seed oil, flaxseed oil, rapeseed oil, primrose oil, linseed oil, avocado oil, a nut oil such as hazelnut oil, walnut oil, macadamia nut oil, or other nut oil, peanut oil, rice bran oil, sesame oil, or combinations thereof. The above oils may be optionally hydrogenated (partially or fully) and optionally inter-esterified.

Optionally, the oil can contain one or more liposoluble compounds; such as for example plant polyphenols, fatty acids, such as n-3 fatty acids, n-6 fatty acids, vitamins, aromas, flavours, antioxidants, other active ingredients. Preferred antioxidants include ascorbic acid, ascorbyl palmitate, citric acid, rosmarin extract, BHA (Butylated hydroxyanisole), BHT (Butylated hydroxytoluene), mixed tocopherol, and EDTA (Ethylenediaminetetraacetic acid).

Preferably, a vegetable oil is used, more preferably an oil with a low SFA content is chosen such as high oleic sunflower oil or high oleic rapeseed oil.

The above liquid oils may have differing oleic acid contents. For example, sunflower oil may be (% by weight): Conventional oil or high linoleic acid: 14.0%<Oleic acid <43.1%, Mid Oleic: 43.1%<Oleic acid <71.8%, High oleic: 71.8%<Oleic acid <90.7%, Ultra/Very-high oleic, 90.7<oleic acid. For example, safflower oil: conventional oil: 8.4%<Oleic acid <21.3%; and High oleic: 70.0%<0leic acid <83.7%. Additionally, high oleic acid variants of the following oils are available, soybean oil (70.0%<0leic acid <90.0%), rapeseed oil (70.0%<0leic acid <90.0%), olive oil (70.0%<0leic acid <90.0%), canola (70.0%<0leic acid <90.0%), and algae oil (80.0%<0leic acid <95.0%). In other embodiments, the liquid oil may be medium-chain triglycerides, preferably triglycerides where the fatty acids have an aliphatic tail of 6-12 carbon atoms. These oils may be obtained from coconut oil, palm kernel oil or milk.

The solid fats used in preparing the first layers of the present invention may be selected from known confectionery fats, cocoa butter equivalents etc. that are known in the art. For examples, Chocofill™ NH18/SG from AAK, lllexao™ SC 70 from AAK, lllexao™ SC 30-69 from AAK, for example.

In a preferred embodiment, the solid fat is present in an amount of the first layer of from 15 wt.% to 50 wt.%, preferably from 20 wt.% to 45 wt.%, most preferably from 25 wt.% to 40 wt.% based on the weight of the first layer.

In an embodiment of the invention, the first layer may contain other fats typically used in confectionery. For example, selected from the group comprising of milk fat, coconut oil, palm kernel oil, palm oil, cocoa butter, butter oil, lard, tallow, oil / fat fractions such as lauric, stearin or olein fractions, hydrogenated oils (partial and full hydrogenation, shea fat, cocoa butter extender fats (for example, approved fats: illipe, kokum gurgi, mango, sal), inter-esterified fats (could be any fats and oils and could be either chemical or enzymatic inter-esterification), and blend of at least two of the above. These fats, if present, are preferably used at 15wt% of the first layer, preferably less than 10wt% and preferably less than 5wt%.

Non-Fat Solids

In an embodiment of the invention, the first layer comprises: from 25 wt.% to 85 wt.% of one or more non-fat solids based on the total weight of the first layer, preferably 30 wt.% to 80 wt.%, most preferably 35 wt.% to 70 wt.%.

For instance, typical savoury first layer compositions may further comprise supplementary ingredients such as salt, maltodextrin, skimmed milk powder, full cream milk powder (FCMP), whey powder, cheese powder, natural or synthetic flavours, natural or artificial colours, starch based fillers, emulsifiers such as lecithin, and other ingredients.

For instance, typical sweet first layer compositions may further comprise supplementary ingredients such as solid fats, sugar, fat, skimmed milk powder, full cream milk powder, whey powder, fruit acids, cocoa powder, natural or synthetic flavors, natural or artificial colors, starch based fillers, emulsifiers such as lecithin, and other ingredients.

The first layer of the invention preferably comprises one or more added sweeteners and/or bulking agents. 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/or polyols (preferably chosen from sorbitol, mannitol, maltitol, isomalt, xylitol or erythritol).

In one embodiment, the one or more added sweeteners and/or bulking agents 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; hydrolysed 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 bulking agent comprises flour, preferably heat-treated flour. In the present invention the term “flour” has the understood dictionary definition, i.e. a powder obtaining by grinding raw grain, roots, beans, nuts or seeds, preferably grain, preferably cereal grain. The term “flour” does not encompass isolate single constituents of the above raw materials, e.g. isolated starches.

In a preferred embodiment, the flour is heat-treated. Heat-treated flour is a commonly understood term in the art that relates to flour that has undergone a treatment to reduce the microbacterial load preferably without gelatinizing the starches.

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 first layer comprises: from 15 wt.% to 65 wt.%, preferably 25 wt.% to 60 wt.%, most preferably 30 wt.% to 60 wt.%, of the one or more added sweeteners.

In preferred embodiments, the first layer comprises an amount of a dairy-based powder, preferably milk powder, of about 5% to 70wt% based on the total weight of the first layer, preferably from about 10% to 60wt%, such as from about 15% to 50wt%, such as from about 20% to 45wt%.

In a preferred embodiment of the present invention, the dairy-based powder is preferably selected from the group consisting of: milk powders of any description (Whole milk powder, whey powder, skimmed milk powder, demineralized whey powder, milk proteins, whey protein isolate, demineralized whey powder permeate, etc); Caramelized and Condensed Milk powder, dried Dulce de Leche; cheese of any kind in powder; Yoghurt powders and mixtures thereof.

In a particular embodiment, the first layer composition comprises cocoa powder, preferably from 1.0% to 70% of cocoa powder by weight, optionally from 2.0% to 20.0%.

In one embodiment, the fat based confectionery first layer comprises an emulsifier. In another embodiment, the emulsifier is soya or sunflower lecithin. In an embodiment, the emulsifier is present in an amount between 0.05wt% and 3.0wt%, and preferably between 0.1 wt% and 1.0wt%.

Confectionery Product

The present invention provides a confectionery product comprising a second layer and a first layer, wherein the first layer is moulded and preferably visible.

The term “visible” has its standard meaning, i.e. can be observed without any product modification.

The term “moulded” has its standard meaning, i.e. made or shaped in a mould. It is clear that this is a product feature that is inherently clear even though it is related to a process feature. It is immediately apparent if a composition has been moulded or has, for example, simply been deposited. In the interests of clarity, the mould and the second layer are not the same, i.e. a separate component is required to manufacture the products of the present invention. The shape of the overall product is controlled by the mould. Hence, the shape of the final product is limited by the mould design. For example, the products of EP2804487 do not contain a moulded filling as the filling is simply deposited into the shell.

In a preferred embodiment, the confectionery product is in the form of a segmented bar (or tablet, these terms are synonymous in the art) comprising the second layer and a series of discrete raised portions of the first layer projecting therefrom and separated by channels.

In a preferred embodiment, the second layer comprises a base layer for the confectionery product. In one embodiment, an upper surface of the second layer forms the lower surface of the channels. The channels are defined between and/or around the discrete raised portions and have a depth equal to the height of the uppermost point of the discrete raised portions of the first layer relative to the second layer.

In a preferred embodiment, the second layer and first layer are in contact in the range of less than 95% of the surface area of the first layer, preferably less than 80%, and more preferably less than 60%. In a preferred embodiment, the second layer and the first layer are in contact in the range of greater than 5% of the surface area of the first layer, preferably greater than 10% and more preferably greater than 20%. Preferably, between 5% and 95%, 10% and 80% and 20% and 60%.

In a preferred embodiment, the weight ratio of first layer to second layer is between 1 :99 and 99:1 , 5:95 and 95:5, 10:90 and 90:10, 20:80 and 80:20, and 30:70 and 70:30.

The nature of the material for the second layer is not particularly limited other than it is a foodstuff material capable of being moulded. In a preferred embodiment, the second layer comprises a fat-based confectionery (e.g. chocolate or compound) or a sugar-based confectionery.

The term "fat-based" confectionery substance is intended herein to mean compositions which comprise a continuous phase, or matrix, of fat. Such substances, in general, comprise fat in an amount of at least about 15% by weight. The substances processed in accordance with the present invention preferably contain at least about 20% by weight fat and may contain up to about 85% to 90% by weight fat, although higher amounts are not intended to be precluded. In general, second layers prepared in accordance with the present invention will contain from about 25% to about 70% by weight fat and more usually, from about 30% to about 60% by weight fat.

The term "sugar-based" confectionery substance is intended herein to mean compositions which comprise a continuous phase, or matrix, of fat. Such substances, in general, comprise sugar in an amount of at least about 15% by weight. The substances processed in accordance with the present invention preferably contain at least about 20% by weight fat and may contain up to about 85% to 100% by weight sugar, although higher amounts are not intended to be precluded. In general, products prepared in accordance with the present invention will contain from about 25% to about 90% by weight fat and more usually, from about 50% to about 80% by weight fat.

In a preferred embodiment, the second layer is a chocolate or chocolate-analogue, e.g. chocolate compound, second layer. These terms are well known in the art but definitions are provided below. The second layer, preferably measured post-demoulding, preferably has a hardness of between 20 N and 75 N at 20°C, preferably between 22 N and 60 N, preferably between 22 N and 50 N, preferably between 22 N and 40 N, preferably between 23 N and 40 N and most preferably between 25 and 35 N. The hardness is measured using the method set out above and used in the examples section.

In an embodiment, the confectionery product further comprises a cap layer on the opposite side of the first layer to the second layer, wherein the cap layer is made of a composition harder than the first layer. The presence of a cap layer enables the consumer to more securely grasp the confectionery product without damaging the first layer and providing a cleaner eating experience.

In a preferred embodiment, the cap layer is made of a material as defined above for the second layer. Similarly, the nature of the material for the cap layer is not particularly limited other than it is a foodstuff material capable of being moulded. In a preferred embodiment, the cap layer comprises a fat-based confectionery (e.g. chocolate or compound) or a sugar-based confectionery.

In a preferred embodiment, the cap layer is a chocolate or chocolate-analogue, e.g. chocolate compound. These terms are well known in the art but definitions are provided below.

The cap layer, preferably measured post-demoulding, preferably has a hardness of between 20 N and 75 N at 20°C, preferably between 22 N and 60 N, preferably between 22 N and 50 N, preferably between 22 N and 40 N, preferably between 23 N and 40 N and most preferably between 25 and 35 N. The hardness is measured using the method set out above and used in the examples section.

In an embodiment, the cap layer may be coloured the same colour as the first layer to reduce any visual distinguishment between the different layers. In an embodiment, compositions of the invention may usefully be chocolate products (as defined herein), more usefully be chocolate or a chocolate compound. Independent of any other legal definitions that may be used compositions of the invention that comprises a cocoa solids content of from 25% to 35% by weight together with a milk ingredient (such as milk powder) may be informally referred to herein as ‘milk chocolate’ (which term also encompasses other analogous chocolate products, with similar amounts of cocoa-solids or replacements therefor). Independent of any other legal definitions that may be used compositions of the invention that comprises a cocoa solids content of more than 35% by weight (up to 100% (i.e. pure cocoa solids) may be informally referred to herein as ‘dark chocolate’ (which term also encompasses other analogous chocolate products, with similar amounts of cocoa-solids or replacements therefor). The term ‘chocolate’ as used herein denotes any product (and/or component thereof if it would be a product) that meets a legal definition of chocolate in any jurisdiction and also include product (and/or component thereof) in which all or part of the cocoa butter (CB) is replaced by cocoa butter equivalents (CBE) and/or cocoa butter replacers (CBR).

The term ‘chocolate compound’ as used herein (unless the context clearly indicates otherwise) denotes chocolate- 1 ike analogues preferably characterized by presence of cocoa solids (which include cocoa liquor/mass, cocoa butter and cocoa powder) in any amount, notwithstanding that in some jurisdictions compound may be legally defined by the presence of a minimum amount of cocoa solids.

The term ‘chocolate product’ as used herein denote chocolate, compound and other related materials that comprise cocoa butter (CB), cocoa butter equivalents (CBE), cocoa butter replacers (CBR) and/or cocoa butter substitutes (CBS). Thus, chocolate product includes products that are based on chocolate and/or chocolate analogues, and thus for example may be based on dark, milk or white chocolate.

Unless the context clearly indicates, otherwise it will also be appreciated that in the present invention, any one chocolate product may be used to replace any other chocolate product and neither the term chocolate nor compound should be considered as limiting the scope of the invention to a specific type of chocolate product. Preferred chocolate product comprises chocolate and/or compound, more preferred chocolate product comprises chocolate, most preferred chocolate product comprises chocolate as legally defined in a major jurisdiction (such as Brazil, EU and/or US).

Preparation of Confectionery Product

The present invention provides a process of preparing a confectionery product comprising at least two layers, wherein said two layers are both moulded, the process comprising:

(a) depositing the first layer in a mould;

(b) depositing a second layer in the mould on top of the first layer;

(c) optional further component addition;

(d) cooling; and

(e) demoulding, wherein both layers have portions directly in contact with the mould until the demoulding step, wherein the first layer post-demoulding has a hardness of between 1.90 N and 20.0 N at 20°C. The process of preparing the first layer is not particularly limited; known processes for combining the ingredients recited above may be used. However, in an embodiment, the first layer preparation comprises a step of heating the initial first layer to a temperature of at least 35°C. Preferably the mixture is heated to a temperature of: from: 35°C to 80°C, from 40°C to 70°C, from 42°C to 65°C, from 42°C to 60°C, and most preferably about 45°C. The purpose of this heating and stirring stage is to ensure the substantially complete, or complete, melting of the fats in the first layer.

The process for preparing the first layer preferably comprises refining steps for ensuring an acceptable particle size. These refining steps are standard in the art.

The process for preparing the first layer preferably comprises a tempering step. The tempering may be carried out by processes and equipment well known in the art. In a preferred embodiment, the tempering is carried out to provide a temper index of between 3.5 and 6.5, preferably between 4.0 and 6.0 and most preferably between 4.5 and 5.5 as measured by a temper meter (e.g. a Sollich Tempermeter E6).

In preferred embodiments, the cooling step (d) is at a temperature of: from -5°C to 20°C, preferably from 0°C to 17°C, preferably from 0°C to 15°C and more preferably from 0°C to 12°C. In a particularly preferred embodiment, the mixture is cooled to a temperature of about 10°C.

In preferred embodiment, the cooling step (d) is carried out for a time period of from 10 minutes to 180 minutes, preferably from 15 minutes to 120 minutes, preferably from 15 minutes to 60 minutes and more preferably from 15 minutes to 60 minutes.

In a particularly preferred embodiment, the mixture is cooled to a temperature of from -5°C to 20°C for a time period of from 10 minutes to 180 minutes and more preferably from 0°C to 15°C from 15 minutes to 60 minutes.

In the embodiment were a cap layer is present, the cap layer material is deposited prior to the first layer material into the mould.

Further Components and Backing Off

The second layer of the products of the present invention may comprise addition of further components that are typical in the confectionery field. For example, the second layer may contain fillings (e.g. fat- or water-based), chocolate, baked foodstuffs (e.g. wafers, biscuits etc), inclusions (e.g. fruits, nuts, rice puffs, etc.), sugar confectionery (e.g. gummies, sugar panned spheres, marshmallows etc.) and combinations thereof. Similarly, the first layer of the products of the present invention may comprise addition of further components that are typical in the confectionery field. For example, the filling may comprise baked foodstuffs (e.g. wafers, biscuits etc), inclusions (e.g. fruits, nuts, rice puffs, etc.), sugar confectionery (e.g. gummies, sugar panned spheres, marshmallows etc.) and combinations thereof. For example, the confectionery product may be a filled confectionery product. For example, one or more of the segments may be hollow and filled with a filling material. The filling material may comprise a third material different from the first layer and second layer materials. The filling material may comprise any suitable filling material, for example, chocolate, caramel, toffee, praline, biscuit, cake, nuts, fruit, cream, icing or any other suitable filling material or combination thereof. The segments may all be filled, or some may be filled. The filled segments may all comprise the same filling material, or the different segments may comprise any number of further filling materials or combinations thereof.

In preferred embodiments, the further components comprise 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.

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/cm ³ . 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 comprises within the second layer a filling layer sandwiched between two wafer layers.

In an embodiment, the second layer is closed off with additional second layer material (i.e. “backing off”). Such process steps are carried out using known processes.

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.

First layer Manufacturing

To make the first layer, the ingredients were weighed out first. The fat was melted at 45°C and mixed with the oil (where present) and remaining solids (e.g. milk powders, sugar, cocoa powder, salt) to a fat level of 24.5% in an industrial mixer (Robot Coupe MP450 L). This premix was passed through a refiner (Buhler SDWC -300) to bring the particle size down to 125 pm (digital micrometre, Mitutoyo). This pre-mix was sent through a refiner for a second time (Buhler SDWC -300) to convert the mass into flake with a final particle size of 27 pm (digital micrometre, Mitutoyo). This flake was liquefied in an industrial mixer (Robot Coupe MP450 L) with the remaining balance of oil (where present), lecithin, flavour (where present), and colour (where present) before being sieved through a 2 mm mesh.

Product Assembly

The moulds are conditioned in a heating cabinet to 29°C. The chocolate is tempered in a tempering unit (Selmi One) to a temper index of 5 ± 1 (Sollich Tempermeter E6), where the heating stage is set to 45°C and the cooling stage usually between 27°C and 29°C, chocolate dependent. The first layer is tempered in a tempering unit (Selmi One) to a temper index of 5 ± 1 (Sollich Tempermeter E6), where the heating stage is set to 45°C and the cooling stage usually between 26 and 27°C, first layer dependent.

Using a piping bag, the first layer is deposited into the central section of the conditioned mould. The mould is then placed on a vibrating table for a short duration (< 5 seconds) to flatten the first layer. Subsequently enough chocolate is deposited over the first layer to fill the cavity halfway. The mould is then placed on a vibrating table for a longer duration (< 60 seconds) to flatten the chocolate and remove any air bubbles. The mould is then placed on a vibrating table for a short duration (< 5 seconds) to flatten the chocolate. Excess chocolate is removed with a scraper. The mould is then cooled for 25 - 30 min at 10°C in a fridge (Weiss-Technik Environmental Chamber) and then demoulded by inverting the mould and twisting gently at ambient conditions of 20°C. The mould prepared a tablet product comprising 6 by 3 segments with a second layer of thickness 8mm and each of the 18 segments having a “flattened” cone (i.e. a cone with the apex section removed) of first layer with a circular base of diameter 25mm and an upper circular face of diameter 15mm with a height of 25mm. The raised portions of the first layer were separated by channels with a minimum width of 6mm between each raised portion. The tablet second layer had breath and length of 99mm by 190mm.

For measuring the SFC values and hardness values, the method described below were used.

For IIIPAC, 2.150A, 80°C = 30 mins, 30°C = 10 mins, 0°C = 30 mins, Each Temperature = 30 mins then take a reading.

For IIIPAC, 2.150B, the information was taken from the supplier’s product specification. For Comparative Example 4, the information is taken from EP2804487.

For hardness, a Stable Micro Systems Ltd., P/2 2mm diameter cylinder was used. The samples were stored for 2 weeks at 16°C. At the testing temperatures the probe speed was 1mm/s to a depth of 8mm.

The properties of the added fat used are shown below in Table 2. As above, solid fat content is measured according to the methods recited.

Accordingly, the method and formulations of the present invention provide a novel confectionery that has first layers with a texture significantly different from chocolate that are capable of being demoulded. The comparative examples do not offer the same combination of distinguished textures and ability to be demoulded.

Example 4 and Comparative Example 6

The following products were made according to the procedure of the previous examples.

The properties of the added fat used are shown below in Table 2. As above, solid fat content is measured according to the methods recited.

Demoulding was assessed over time periods of 20, 30, 45 and 60 minutes at 10°C. Comparative Example 6 was inferior to the examples within the present invention over all demoulding assessments. The ease of demoulding improved over extended cooling times.

Measurement of Contraction: Example 5 and Comparative Example 7

The following products were made according to the procedure of the previous examples.

The contraction degree percentages of Example 1 and Comparative Example 7 were calculated using the ChocoAnalyser (Aasted) according to the following method. The empty measurement cup was preheated in the instrument to 28 °C, the same temperature as the sample to be tested. Upon reaching the required temperature, the measurement cup without the lid was placed on a scale with the required metal bead for contraction measurement placed in the recess in the centre of the cup. The combined weight was fared to reset the scale. The first layer (10.6 g) was added to the measurement cup ensuring no mixture entered the metal bead. This was the weight that was equivalent to 8ml. The cup was tapped on a table surface to get the first layer to spread. The lid was placed on the cup before placing the cup in the contraction meter, ensuring that the metal bead remained in the centre. The cover was closed, locked and the Standard Contraction test started.

It was found that Example 1 had a contraction degree percentage of 0.83% and demonstrated good release when demoulded. Comparative Example 7 had a contraction degree percentage of 0.18% and demonstrated very poor demoulding performed under the same conditions described above. Example 6

A moulded product as prepared in Example 1 was modified by first depositing 4 mm of the second layer chocolate as a cap layer in the mould prior to deposition of the second layer. The caper layer acted to aid the breaking of the tablet and protected the softer first layer to ensure a clean eating experience.