Method of tropicalizing chocolate Field of the invention

The present invention relates to tropicalizing agent compositions, to methods for the preparation thereof, to methods of tropicalizing chocolate or analogues thereof, and to chocolate or analogues of chocolate containing the tropicalizing agents. In particular, it relates to the use of a novel combination of cocoa particles and the methods of the invention and to their incorporation into tropicalizing agent compositions and products of the invention.

Background of the invention

Conventionally manufactured chocolate consists of sugars, cocoa solids and protein (usually from milk) homogeneously dispersed in fats and fatty substances originating from cocoa butter. Chocolate analogues contain other vegetable fats in partial/total replacement of the cocoa butter fat. Often the continuous fat phase also contains dairy fat.

Cocoa butter typically starts to soften at about 28°C, with consequent loss of the mechanical strength of the chocolate. This means that at the high ambient temperatures frequently encountered in tropical countries, chocolate becomes sticky or even runny. It tends to stick to the wrapper and fall apart when the wrapper is removed, leaving a semi-liquid mass that can often only be eaten with a spoon if cleanliness is desired. Enrobed chocolate products typically lose integrity under these conditions, with their contents often leaking and individual units tending to stick together in the packaging. Chocolate also loses the ‘snap’ that is an important (and pleasurable) textural characteristic of chocolate stored and eaten under cooler conditions.

Attempts to produce a chocolate that is resistant to heat are numerous. Persons skilled in the art generally refer to methods to achieve chocolate or chocolate analogues that are heat resistant as to methods to tropicalize chocolate. The approaches most widely used can be divided two main groups: 1) incorporation of high-melting point fats; and 2) creation of a three- dimensional matrix or network of sugar crystals or protein particles that will act as a sponge and hold the fat - thus maintaining the structure of the product even on melting of the fat. Over the last century many different methods have been reported.

There are two major drawbacks to the use of high-melting fats in chocolate. Namely that food regulations in many countries restrict the use of substitutes for cocoa butter in chocolate. Secondly, the high-melting point fats in chocolate-like products give an unpleasant waxy mouthfeel.

Many methods have been described for causing accretion of sugar crystals by adding water or a polyol to chocolate, as originally disclosed in DE 389127. CH 409603 describes the direct incorporation of water into liquid chocolate mass during production causing a rapid increase in viscosity. As a result, it is impossible to pour the material into moulds or use for enrobing.

EP0189469 describes the mixing of a liquid polyol with tempered conventional chocolate mass before depositing it into molds. Polyols that are liquid at ambient temperatures (such as glycerol) are preferred, though the patent teaches that higher melting polyols (such as sorbitol) can also be used. The mixture is held at slightly elevated temperatures (24°C to 35°C) for a short period of time during which the viscosity rises. This is stated to be the result of a chemical reaction between the fat and the polyol. The time and temperature of the holding period are critical parameters that control the viscosity increase - the viscosity must remain low enough for the subsequent molding or enrobing operations.

In the method described by US5,445,843 a polyol (such as glycerol) is encapsulated by emulsifying it with a liquid fat (such as molten cocoa butter) and lecithin as an emulsifier, then spray-chilling the emulsion. The emulsion “capsules” (which have an average diameter 100 microns) are added to liquid chocolate mass to achieve a polyol content of from 0.2 to 5% by weight. The product was reported to have remained liquid for several minutes.

The use of emulsification to avoid too rapid an incorporation of water into the chocolate mass is described in US4,446,166. An oil-in-water emulsion (typically 50% water, 50% fat) is prepared with cocoa butter using lecithin as the emulsifier. The emulsion is cooled and milled to give partially or entirely solid particles that are then added to the chocolate mass at levels of between 2 and 10%. Once incorporated in the warmer liquid chocolate mass, the emulsion particles will melt, releasing the water droplets. A disadvantage of this method is the need to guarantee a homogeneous distribution of the emulsion particles before they melt. Premature release of water causes a sudden increase in viscosity that renders the chocolate unsuitable for molding or enrobing.

EP0297054 describes a method for homogeneously dispersing water by using an aqueous foam. The foam is stabilized with an edible foaming agent (such as egg albumin) and added to conventionally prepared chocolate mass after tempering. The foam is added at levels that deliver from 0.5 to 2% of water, reportedly with no noticeable increase in viscosity to provide a treated chocolate usable for molding or enrobing. The trapped gases can be removed from the still liquid product by exposing it to reduced pressure. EP0407347 describes a similar method.

EP0393327 discloses another variation in which the aqueous phase of the water-in-oil emulsion contains sugars (such as sucrose or glucose) or polyols (such as sorbitol). The emulsion is prepared with 30 to 60% fat using emulsifying agent at a level of 0.1 to 3%. Described suitable emulsifying agents are lecithin, glycerol fatty acid ester, polyglycerol fatty acid ester, polyglycerol condensed ricinoleic acid ester and sucrose fatty acid ester that has an HLB not more than 7. The level of sugar or polyol in the aqueous phase of the emulsion can be between 20 and 60% and the level of water between 15 and 25%. The sugar or polyol in the aqueous phase is reported to provide smoother texture to the heat-stable chocolate mass. A storage period of about 20 days, however, is required for proper development of internal structure.

A similar method is disclosed in EP0442324, whereby an oil-in-water emulsion is prepared by mixing 30-80% of an oil or fat (for example, cocoa butter) in water containing a small amount of a suitable emulsifier. This emulsion is mixed at a level of about 5% with a conventionally manufactured and tempered chocolate mass that is then molded. It is stated to be important to control the temperature to be no higher than 90°F to keep the oil-in-water emulsion stable. The homogeneously dispersed water generates a viscosity increase of the chocolate mass during solidification of the finished product. However, it is still necessary to store the molded product for several days to establish heat stability.

US5,486,376 describes the use of water-in-oil microemulsions to introduce finely dispersed water into chocolate mass. Similarly, US6, 159,526 describes addition of water to the chocolate as a water-in-oil emulsion stabilized by sucrose fatty acid esters (HLB < 3). US 6,159,526 is concerned primarily with adding water-based flavors to chocolate.

WO 93/06737 describes methods for making gels/pastes by adding water to “Raftiline” (inulin), starches (potato and corn), “Splendid” (pectin), or Gum Arabic. The paste is then mixed into tempered chocolate that is molded.

US5,468,509 describes a method for adding up to 16% water to chocolate. The chocolate supposedly remains moldable. Two mixtures are prepared. (1) Cocoa is coated with cocoa butter in the presence of an emulsifier and (2) water, a sweetener and milk solids are blended to form an aqueous phase. The two are gently blended and the product molded. US5,965,179 aims to circumvent the problems of viscosity increase on the addition of water to chocolate by use of an extruder for processing the chocolate. The water is added as an aqueous gel with microcrystalline cellulose. This gel is injected into the chocolate using a twin- screw extruder so as to form a viscous product containing 3 to 20% of added water.

US2005/0118327 describes the preparation of gel beads comprising 20-50% sugar or polyol, water, emulsifying agent and a gelling agent (hydrocolloids). The gel beads are formed by dispersing a hot aqueous sol (90°C-95°C) in a liquid fat in a high shear mixer, to form an emulsion, and then cooling to get gelification of the beads. The gel beads dispersed in fat are blended into molten chocolate mass. One drawback is that the release of the sugar/polyol syrup from the gel beads, requires activation. US2005/0118327 teaches the activation of gel bead degradation by freezing at temperatures of -5°C to -15°C. It is reported that without this cooling it is necessary to store the products for 10-14 days to develop shape retention properties.

In another approach, W091/19424 describes the preparation of gel beads comprising alginate or pectate, divalent metal ions and a sequestrant for the metal ions. The gel beads are used as fat substitutes.

EP0688506 describes the preparation of gels comprising polyol or polyol/water with gelling agents and alkali or alkali-earth metal salts. The gels are produced by heating to temperatures of 120°C and are then frozen in liquid nitrogen, before addition to liquid chocolate. These prior art references have drawbacks such as the release of water into the chocolate mass, which occurs early in the process and is not retarded for long enough for the material to be used for typical enrobing processes; the dispersion and release of water is not under sufficiently fine control to avoid development of unpleasantly gritty textures in the final product; and/or activation or an inconveniently long storage time is required for full development of the structures required to provide stability.

EP0393327 discloses making an emulsion out of a saccharide and an emulsifying agent and then maturing the chocolate. US5486376 discloses making an emulsion out of monglyceride (50-65%)/lecithin(0-10%)/chocolate fat (CBE/CBR/CB) (15-20%) and water (15-20%). WO2011010105 relates to adding water and propylene glycol to molten chocolate. US4446166 uses water in fat emulsion, where 20% of fat is in solid form.

Many of the processes are complex, or require additional steps in the production procedure, and/or require the use of emulsifiers and/or gelling agents.

The associated need to provide a tropicalizing agent that delays any substantial increase in viscosity so that the materials can be used for conventional moulding or enrobing processes and that provides a suitable texture and stability, or integrity, in a chocolate product, has been partially addressed by the tropicalizing agent and methods disclosed in the international patent publication WO2013/045523.

However, this prior art method displays disadvantages in the time period required for maturation prior to the commercial release of the product, i.e. , the product must be stored under certain conditions to ensure that the tropicalizing agent is able to act effectively. Additionally, the product requires the addition of additional fibrous materials, which may adversely impact organoleptic properties further.

Accordingly, the present invention is envisaged with the focus of solving the above technical problems. Summary of the invention

The inventors have developed a further improved route to introduce a humectant into chocolate or an analogue thereof to obtain a heat resistant (tropicalized) chocolate or analogue thereof, which displays improvements in respect of heat resistance without maturation and adversely impacting other properties of the chocolate.

According to one aspect of the invention, there is provided a tropicalizing agent composition comprising a fat component, a cocoa solids component and a humectant, wherein the composition comprises between 10wt% and 60wt% of the cocoa solids component based on the weight of the composition.

In another aspect, the invention provides a process for preparing a tropicalizing agent composition according to the present invention comprising steps of (a) mixing the cocoa solids with the fat component, preferably at a temperature that the fat component is liquid, (b) optionally cooling the mixture, (c) adding the humectant to the mixture, optionally at an elevated temperature and (d) mixing the components..

In another aspect the invention encompasses the use of the tropicalizing agent composition according to the present invention for improving the heat stability of a chocolate or chocolate analogue product.

According to another aspect of the present invention, there is provided chocolate or chocolate analogue product comprising a tropicalizing agent composition according to the present invention.

In another aspect, the present invention provides a process for tropicalizing chocolate, or an analogue thereof, by combining a chocolate or a chocolate analogue mass, optionally a tempered chocolate mass or untempered chocolate analogue mass, with a tropicalizing agent composition according to the present invention so as to increase the structure of the tropicalized chocolate mass. Preferably, the amount of tropicalizing agent composition is sufficient to increase the shape retention of the tropicalized chocolate mass compared to a non-tropicalized mass.

Detailed description of the invention

Definitions

According to the present invention, the terms “chocolate product” and “chocolate analogue product” identify respectively chocolate or chocolate analogue based products (also conventionally known as “compound”). Chocolate and chocolate analogue products of the invention include but are not limited to: a chocolate product, a chocolate analogue product (e.g. comprising cocoa butter replacers, cocoa-butter equivalents or cocoa-butter substitutes), a chocolate coated product, a chocolate analogue coated product, a chocolate coating for biscuits, wafers or other confectionery items, a chocolate analogue coating for biscuits, wafers or other confectionery items and the like.

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) denote chocolate-like analogues 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.

In an embodiment, the chocolate product, of the present invention comprises cocoa butter (or equivalent as described above) by weight of the confectionery material in at least 5.0% by weight, preferably at least 10.0% by weight, preferably at least 13.0% by weight, more preferably at least 15.0% by weight, for example at least 17.0% or at least 20%.

The preferred maximum amount of cocoa butter (or equivalent as described above) present in the chocolate product of the present invention is less than 35.0% by weight, preferably not more than 30.0% by weight, more preferably not more than 30.0% by weight, and most preferably not more than 25.0% cocoa butter by weight of the chocolate product. For example, between 10.0wt% and 35.0wt% of the chocolate product.

In an embodiment, the chocolate product comprises between 0% and 95% by weight of the confectionery product of cocoa mass dependent on the end product, preferably between 0% and 85%, for example, between 45% and 80%, less than 5% or between 8% and 12% by weight of the chocolate product of cocoa mass.

Generally, the chocolate product of the present invention comprises at least 10.0% by weight, preferably at least 13.0% by weight, more preferably at least 15.0% by weight, and even more preferably at least 17.0% cocoa mass by weight of the chocolate product.

The preferred maximum amount of cocoa mass present in the chocolate product of the present invention is less than 35.0% by weight, preferably not more than 30.0% by weight, by weight, and most preferably not more than 25.0% cocoa mass by weight. For example, between 10.0wt% and 35.0wt% of the chocolate product.

If the chocolate product is a white chocolate product, the amount of cocoa mass is lower than that above, preferably not present.

In an embodiment of the present invention, the chocolate product comprises a milk-based component, preferably the milk-based component is selected from the group consisting of non fat milk solids, milk powder (optionally full cream, skimmed or semi-skimmed) and milk fat and combinations thereof. This milk-based component may be present between 0wt% and 60wt%, optionally between 10wt% and 50wt% of the chocolate product.

In an embodiment of the present invention, the chocolate product comprises a sugar, preferably in an amount of between 10wt% and 60wt% of the chocolate product.

A chocolate product of the present invention may include between:

5.0wt% and 35.0wt% cocoa butter,

10.wt% and 35.0wt% cocoa mass,

10wt% and 60wt% sugar,

0wt% and 60wt% milk-based component,

1.0wt% and 20%wt% of the tropicalizing agent composition.

In a preferred embodiment of the present invention, the cocoa butter, cocoa mass, sugar and milk-based component mentioned above provide between 75wt% and 99.9wt% of the chocolate product composition, preferably between 80wt% and 98wt% and preferably between 90wt% and 95wt%. In a preferred embodiment, any cocoa butter and/or cocoa solids present in the tropicalizing agent composition contribute to the above-mentioned percentages of cocoa butter and cocoa mass, i.e. are not present in addition.

The chocolate or chocolate analogue product may be in form of a moulded tablet, a moulded bar, an aerated product, or a coating for confectionery products, wafer, biscuits, among others. It may also have inclusions, chocolate layers, chocolate nuggets, chocolate pieces, chocolate drops. The chocolate or chocolate analogue product may further contain crispy inclusions e.g. cereals, like expanded or toasted rice or dried fruit pieces.

The terms “tropicalization”, “tropicalizing methods”, and variations thereof as used herein, refer to methods and processes of the invention to achieve heat and shape resistance in chocolate or chocolate analogue products.

The term “tropicalized products”, and variations thereof as used herein, refers to chocolate and chocolate analogue products of the invention which are endowed with heat and shape resistance.

The term "tropicalizing agent composition" as used herein, generally refers to suitable materials according to the invention. In particular, it refers to a composition that increases the stability, or structural integrity, in a tropicalized food product into which it is incorporated. In a preferred embodiment, the tropicalizing agent composition is not chocolate or a chocolate product.

The D90 value is a common method of describing a particle size distribution. The D90 is the diameter where 90% of the mass of the particles in the sample have a diameter below that value. In the context of the present invention, the D90 by mass is equivalent to the D90 by volume. The D90 value may be measured for example by a laser light scattering particle size analyser. A preferred method is given in the examples section.

Preferred Embodiments

As it will be apparent to the person skilled in the art, all embodiments and preferred embodiments here below described apply also to the different aspects of the invention mutatis mutandis and may all be combined between each other.

The present invention provides tropicalizing agent composition comprising a fat component, a cocoa solids component and a humectant, wherein the composition comprises between 10wt% and 60wt% of the cocoa solids component based on the weight of the composition.

In a preferred embodiment, the cocoa solids are present in an amount of preferably between 15wt% and 55wt% based on the weight of the composition, preferably between 20wt% and 45wt%, preferably between 25wt% and 40wt% and preferably between 30wt% and 40wt%.

In the present invention the term cocoa solids has the standard meaning in the art, i.e. the components of the cocoa beans remaining after the cocoa butter fat component has been removed. Cocoa liquor is pure cocoa mass, preferably in solid or semi-solid form, which contains both cocoa solids and cocoa butter. In a preferred embodiment, the cocoa liquor comprises between 40wt% and 60wt% cocoa solids and between 40wt% and 60wt% cocoa butter, preferably between 45wt% and 55wt% cocoa solids and between 45wt% and 50wt% cocoa butter

In a preferred embodiment of the invention, the humectant is present in an amount of between 2.5wt% and 40wt% based on the weight of the composition, preferably between 4.5wt% and 30wt%, preferably between 6.5wt% and 25wt%, preferably between 8.0wt% and 20wt% and preferably between 10wt% and 18wt%. The above amounts relate to the total amount of humectant present, i.e. if there is a mixture of humectants the total combined weight is within the above ranges.

Suitable humectants according to the present invention are food grade humectants liquids. Examples of humectants according to the invention include propylene glycol, polyethylene glycol, polyols such as glycerol and sugar alcohols such as sorbitol, xylitol, maltitol, mannitol, sugar solution such as fructose, dextrose, galactose, or any mixture thereof.

In some highly preferred embodiments, the humectant is a polyol. A preferred polyol is glycerol. However other polyols are envisaged such as sugar alcohols, e.g. sorbitol, xylitol, erythitol, maltitol, mannitol. According to certain embodiments, the polyol is selected from glycerol, sorbitol, xylitol or any mixture thereof. According to other embodiments, the humectant liquid is propylene glycol. According to some embodiments, the humectant is a mixture of a polyol, such as glycerol, together with another humectant liquid, such as another polyol and/or propylene glycol.

In a preferred embodiment, the humectant is a polyol and is present in an amount of between 2.5wt% and 40wt% based on the weight of the composition, preferably the humectant comprises glycerol and the humectant is present in an amount of between 4.5wt% and 30wt%.

According to one embodiment of the invention, water and liquid humectant may be used in a mixture ratio. According to one embodiment the tropicalizing agent composition comprises water and a humectant liquid in a water: humectant ratio of from 1:10 to 10:1 w/w, preferably in a water: humectant ratio from 1 :2 to 2:1 w/w, for instance in a water: humectant ratio of about 1 :1. According to one embodiment the tropicalizing agent composition comprises water and a polyol in a water: polyol ratio of from 1:10 to 10:1 w/w, preferably in a water: polyol ratio from 1 :2 to 2:1 w/w, for instance in a water: polyol ratio of about 1 :1.

In a preferred embodiment of the invention, the fat component is present in an amount of between 20wt% and 80wt% based on the weight of the composition, preferably between 25wt% and 75wt%, preferably between 30wt% and 70wt%, preferably between 35wt% and 65wt% and preferably between 40wt% and 60wt%. The above amounts relate to the total amount of fat present, i.e. if there is a mixture of fats the total combined weight is within the above ranges.

The liquid fat component can be any vegetable fat or oil suitable for use in edible foods. The fat component should be compatible with the chocolate or chocolate analogue to which it will be added. Suitable fats include cocoa butter, cocoa butter equivalents (CBE), cocoa butter substitutes (CBS), vegetable oils and butter oils amongst others. Suitable CBE and CBS are widely commercially available. Examples of CBE include Coberine™ (Loders Croklaan), and lllexao™ SC70 (AarhusKarlshamn). Examples of CBS include the Palkena™ Range and Melano™ Range (Fuji Oil).

Preferably, the liquid fat includes cocoa butter, particularly where the tropicalizing agent or tropicalizing agent composition will be used in chocolate products. In one preferred embodiment, the liquid fat is cocoa butter and tropicalizing agent compositions are included in regular chocolate, rather than chocolate analogues.

However, the liquid fat can include one or more cocoa butter substitutes, particularly where the tropicalizing agent or tropicalizing agent composition will be used in chocolate analogues. In another embodiment, the liquid fat preferably includes one or more vegetable fats, e.g., non- lauric vegetable fats. Where the tropicalizing agent or tropicalizing agent composition will be used in a chocolate analogue, the vegetable fat is preferably the same fat or at least one of the same fats, used in preparing the chocolate analogue mass so as to increase the compatibility and stability of the tropicalized chocolate mass. In a preferred embodiment of the invention, the fat component is selected from the group consisting of cocoa butter, cocoa butter equivalents (CBE), cocoa butter substitutes (CBS), vegetable oils and butter oils or any mixture thereof.

In one preferred embodiment the liquid fat is cocoa butter. The use of cocoa butter as the liquid fat component of the tropicalizing agent is particularly preferred for the preparation of a chocolate product, whereby food regulations in many countries restrict or forbid the addition of other fats to chocolate mass. In another preferred embodiment, the liquid fat includes one or more vegetable fats that are the same as a fat used in preparing a chocolate analogue mass, e.g. for a chocolate compound or compound coating product, so as to increase the compatibility and stability of the tropicalized chocolate analogue mass.

In a preferred embodiment, the tropicalizing agent composition comprises between:

10wt% and 60wt% of the cocoa solids,

20wt% and 80wt% of the fat component, and 2.5wt% and 40wt% of the humectant.

In a preferred embodiment, the three components mentioned above provide between 75wt% and 100wt% of the tropicalizing agent composition, preferably between 80wt% and 100wt% and preferably between 90wt% and 100wt%.

In a preferred embodiment, the weight ratio of cocoa solids to humectant is between 0.25:1 and 24:1, preferably between 0.5:1 and 20:1, preferably between 1 :1 and 15:1 and preferably between 1.5:1 and 10:1.

In a preferred embodiment, the weight ratio of cocoa solids to fat component is between 0.4:1 and 2.4:1, preferably between 0.45:1 and 2.0:1, preferably between 0.5:1 and 1.5:1 and preferably between 0.55:1 and 1.0:1.

In a preferred embodiment, the weight ratio of cocoa solids to humectant is between 0.5:1 and 20: 1 and the weight ratio of cocoa solids to fat component is between 0.45: 1 and 2.0:1.

In a preferred embodiment, the tropicalizing agent composition comprises between:

10wt% and 60wt% of the cocoa solids,

20wt% and 80wt% of the fat component, and

2.5wt% and 40wt% of the humectant, the weight ratio of cocoa solids to humectant is between 0.5: 1 and 20: 1 and the weight ratio of cocoa solids to fat component is between 0.45: 1 and 2.0:1 and three components mentioned above provide between 75wt% and 100wt% of the tropicalizing agent composition.

Advantageously the tropicalizing agent composition of the present invention can be prepared from the above-described food ingredients and does not require the use of any emulsifying agent, gelling agent, nor other additive.

In a preferred embodiment, the tropicalizing agent is in the form of an emulsion, preferably with emulsion droplet sizes D90 of between 20 and 100 microns, preferably between 25 and 80 microns, preferably between 30 and 60 microns. As shown in the examples, these ranges provide advantageous properties in respect of heat resistance. The method set out in the examples may be used to measure this particle size.

The present invention provides a process for preparing a tropicalizing agent composition comprising steps of (a) mixing the cocoa solids with the fat component, preferably at a temperature that the fat component is liquid, (b) optionally cooling the mixture, (c) adding the humectant to the mixture, optionally at an elevated temperature and (d) mixing the components.

In an embodiment of the process, the temperature of step (a) is greater than 40 degrees Celsius, preferably greater than 45 degrees Celsius, preferably greater than 50 degrees Celsius, and preferably greater than 55 degrees Celsius. In an embodiment, the temperature is less than 75 degrees Celsius, preferably less than 70 degrees Celsius, and preferably less than 65 degrees Celsius. For instance, where the fat component is cocoa butter a temperature of 40°C or above, such as around 50°C may be preferred. Where a fat component, such as an oil, which is liquid at room temperature, is used then the preparation of the tropicalizing agent can be carried out at room temperature, i.e. without any heating.

In an embodiment, the cooling in step (b) is to a temperature of between 45 and 65 degrees Celsius. In a preferred embodiment, the elevated temperature in step (d) is within the same ranges as the temperature specified above for step (a).

In an embodiment of the process, the cocoa solids and at least a portion of the fat component are added in step (a) in the form of cocoa liquor. In a preferred embodiment, the portion of the fat in the form of cocoa liquor is between 25wt% and 90wt%, preferably between 45wt% and 80wt% relative to the total amount of fat added.

In an embodiment of the process, the cocoa liquor has a particle size D90 of between 10 microns and 40 microns, preferably between 15 and 30 microns. The method set out in the examples may be used to measure this particle size.

An emulsion of the humectant component in fat component can be carried out by simple mixing of the components with agitation, for instance in conventional mixing/blending apparatus. Optionally an emulsifying agent may be added in order to facilitate emulsion formation. The emulsifier component can be any suitable emulsifier. Preferably, the emulsifier component includes lecithin, e.g. soy lecithin. The emulsifier, when used, is typically present in the tropicalizing agent composition in an amount from about 0.001 to 2 weight percent, preferably from about 0.10 to 1 weight percent, for example 0.10 to 0.5 weight percent based on the total weight of the tropicalizing agent composition.

Preferably, the prepared tropicalizing agent composition can be maintained molten for later addition to a liquid chocolate mass. Alternatively, the tropicalizing agent composition can be allowed to cool and solidify for storage and distribution, and can be re-melted for addition to liquid chocolate, or can be particulated or flaked for ‘dry’ addition to liquid chocolate, upon which the fat melts and the particles disperse.

Advantageously the tropicalizing agent composition is suitable for use in chocolate, whereby food regulations in many countries restrict or forbid the addition of artificial additives to chocolate.

Advantageously, the tropicalizing agent composition may be added to a chocolate mass (or chocolate analogue mass) without inducing any significant increase in viscosity of the liquid chocolate mass over time, such that the chocolate mass can be worked and moulded, or used for enrobing, in conventional industrial production processes, whilst at the same time providing a chocolate product that exhibits improved shape stability at elevated temperatures above room temperature, e.g. at temperatures up to 40°C, and even at higher temperatures. By "significant increase" it is meant a viscosity increase that would prohibit a conventional moulding or enrobing process. Preferably, the viscosity increase is less than about 20 percent, more preferably less than about 10 percent. The chocolate product is dry to the touch and does not stick to its wrapper, or adopt the shape of the wrapper, even when exposed to temperatures above the melting range of the fat composition. Advantageously good texture and organoleptic properties of regular chocolate are retained.

The tropicalizing agent composition of the invention can be added to liquid chocolate either before, after, or in combination with tempering of the chocolate. Increase in viscosity of the chocolate following addition of the agent is delayed to such a degree as to permit the tempering process (manually or by machine, thermally/mechanically or by addition of seeding agent or pre-crystallised chocolate mass) without making the chocolate subsequently unworkable and without blocking the tempering machine and its associated pipes and pumps.

In a preferred embodiment, the addition of the tropicalizing agent composition must be added subsequent to conching of the chocolate or chocolate analogue. The conche combination of sustained temperature and high shear destroys some of the internal structures of the tropicalizing agent composition so that it can no longer provide heat stability.

The tropicalizing agent composition of the invention can be added to liquid chocolate or chocolate analogue and dispersed by agitation, either manual agitation and/or with use of standard conventional mixing apparatus. Advantageously the fat-based tropicalizing agent or composition is readily dispersed in a liquid chocolate or chocolate analogue to provide a substantially uniform and homogeneous dispersion of the food particles through the liquid chocolate mass.

Advantageously tropicalization of chocolate or chocolate analogues according to the present invention uses simple and cost effective processes, suitable for industrial application, requiring no harsh conditions or expensive machinery. Advantageously the tropicalizing agent composition of the present invention requires only few ingredient components, and can be prepared with commercially available food ingredients. No expensive additives are required.

According to a preferred embodiment of the present invention, the humectant may be used in an amount of between 0.1 and 5% by weight within the chocolate or chocolate analogue based on weight of the final chocolate or chocolate analogue product, preferably between 0.2wt% and 4.5wt%, preferably between 0.35 wt% and 3.5wt%, preferably between 0.40wt% and 2.5wt%, preferably between 0.45wt% and 2.0wt%, preferably between 0.5wt% and 1.0wt%.

According to a preferred embodiment of the present invention, the tropicalizing agent composition may be added in an amount of between 1.0 and 20% by weight within the chocolate or chocolate analogue. Preferably, they are used in an amount of between 2.0wt% and 15wt%, preferably between 2.5wt% and 17.5wt%, preferably between 2.75wt% and 15.0wt%, preferably between 3.0wt% and 12.0wt%, and more preferably between 3.0wt% and 10wt%.

In one variant of the process, the dispersion of cocoa solids in a portion of the liquid fat component is blended with an emulsion of the humectant component in a second portion of the liquid oil component.

Addition of too much tropicalizing agent or composition, or of tropicalizing agent or composition which contains a too high proportion of water and/or humectant liquid component to particulate carrier component, can tend to cause too rapid an increase in viscosity, particularly if multiple of these factors are present, for the product to be suitable for moulding, enrobing, or both. Addition of too little tropicalizing agent or composition can cause a delay in the time over which the desired heat shape stability properties are developed, or even failure to produce the desired heat stability properties.

According to one embodiment, the fat content, e.g. cocoa butter content of the starting chocolate mass, to which the tropicalizing agent composition is to be added, is reduced compared to the desired final fat content, by an amount such that the fat content, e.g. cocoa butter, of the tropicalizing agent or composition provides the remaining fat amount, to produce a final chocolate product having the desired fat content.

Advantageously, the resultant chocolate products including the tropicalizing agent composition of the invention do not stick to a wrapper, or adopt the shape of the wrapper, at elevated temperatures, even at temperatures as high as 40°C, do not result in adverse appearance or mouthfeel, and in chocolate or analogues thereof do not have adverse effects on bloom. Moreover, the tropicalized chocolates and chocolate analogues have improved shape retention at elevated temperature, even at temperatures as high as 40°C compared to corresponding regular chocolate or chocolate analogue product without the tropicalizing agent.

The tropicalizing agent composition of the invention can be added to any type of chocolate e.g. white, milk, dark chocolate or any intermediate, or any type of chocolate analogue e.g. compound coating. The heat resistance can be expected to develop most effectively in masses containing a high proportion of sugar and milk particulate solids of fine granulometry and relatively low fat content due to the loading and proximity of the building blocks of the particle network.

The tropicalized chocolate and chocolate analogues of the invention can advantageously be used in tropical countries where hot weather causes frequent or rapid melting of chocolate, chocolate analogues. For example, chocolate analogues including coatings and covertures, which are thin and tend to melt rapidly, can surprisingly and advantageously be formed with the tropicalizing agent of the invention. The tropicalized food products of the invention remain non-sticky so as to smoothly slide out of a wrapper and to avoid leaving food product on the consumer's fingers during consumption.

The term "about," as used herein, should generally be understood to refer to both numbers in a range of numerals. Moreover, all numerical ranges herein should be understood to include each whole integer within the range and the end points of the range, unless otherwise specified.

All patent and non-patent references cited in the present application, are hereby incorporated by reference in their entirety.

The invention will now be described in further details in the following non-limiting examples.

Examples

Reference Example 1 :

A reference composition was prepared with a composition as follows and using a 3 roll refiner and Lipp Mischtechnichnik GmbH conchee:

Examples

In order to prepare the tropicalizing agent composition cocoa liquor is heated to 60°C and cocoa butter is added until liquid and cooled to about 50°C. Glycerol warmed to approx. 50°C is added under high shear (in Hobart planetary whisk) and the mixture is mixed for 3 minutes.

The agent is combined with liquid chocolate post-temper, unless specified.

The chocolate compositions are stored for one week at ambient conditions (20°C and 50 percent humidity).

Heat shock measurement. Placed in stove at a set temperature for 1 hour. Removed from stove and hit against flat surface twelve times to cause loss of shape. Reference always present on tray. Data given is in pixels, gives area increase. The larger the figure the less heat stable the mixture created is

Unwrapping measurement. Placed in stove at set temperature for 1 hour. Visual assessment performed based on mass stuck to wrapper and loss of logo definition when wrapped in standard foil.

Particle size analysis. Carried out using a Malvern Mastersizer 3000E, Fraunhoffer Theory, Hydro SM attachment, AAK Akomed R MCT oil dispersant (Rl 1.45). In the wet system the sample is placed in the MCT oil and sonicated for 2 minutes with an ultrasonic probe before being run in the Malvern 3000E (in duplicate).

Mould size is 25mm by 25mm squares with a depth of 7mm. The pixel area of the standard square is 26228 for initial testing (Examples 1&2). From the conching trials onward (including particle size variation and the shelf-life/composition DoE), the camera was adjusted and a new standard was taken at 22000 pixels (all other examples in patent).

Examples 1 and 2

The following components were mixed by weight: Cocoa Butter: 1 part; Cocoa Liquor: 4 parts (2 parts Cocoa Butter 2 parts cocoa solids); Glycerol: 1 part. Therefore: 17% Glycerol, 50% Fat, 33% Cocoa Solids using the above method.

This mixture is then added at 6% to a tempered chocolate mass made using the above recipe with reduced cocoa liquor and butter to have the only recipe change be 1% glycerol addition.

A portion of the agent is matured in a 45°C hot room for 24 hours and a chocolate product is prepared as above. Reference Example 2 uses the same base chocolate but uses a commercially available cocoa butter improver, lllexao Sal, a previously used tropical ization agent.

Heat shock tests were carried out for a range of temperatures and the pixel measurements shown below: Hence, the sample containing matured tropicalization agent performs slightly better but there is a significant benefit provided for added complexity of process. Accordingly, the present invention offers advantages over known methods where maturation is needed to ensure an acceptable product.

Examples 3 to 5

The following trials were carried out based on the above recipes with the position of addition of the tropicalizing agent of the present invention being changed.

Changing point of addition of tropical ization mixture greatly effects heat stability. Reference and ‘start of conche’ have similar heat stability profiles, indicating that the conche combination of sustained temperature and high shear damage the integrity of the tropicalizing agent and its subsequent effect. The sample at the end of the conche has a similar profile to the tropicalized chocolate where the agent was added at tempering.

Examples 6 to 9

The above processes were repeated with the mixing and shear rates controlled to provide emulsions of different particle sizes. The particle sizes were measured using the above parameters and chocolates prepared and heat shock tested at 37°C.

As can be seen, if emulsion particle size is smaller, greater heat stability will be achieved.

Example 10

A study was carried out to compare the impact of the amount of lecithin, amount of glycerol and maturation time since moulding using heat shock tests at 37°C. The wt% are based on the chocolate composition weight.

The p value for the interaction between Lecithin and Week is 0.576, which indicates the relationship between Lecithin and Week does not depend on the value of Lecithin and Week (i.e. no interaction). The p value for the interaction between Lecithin and Glycerol is 0.01 , which indicates the relationship between Lecithin and Glycerol does depend of the value of Lecithin and Glycerol (i.e. .an interaction). The p value for the interaction between Week and Glycerol is 0.00, which indicates the relationship between Week and Glycerol does depend of the value of Week and Glycerol (i.e. an interaction).

The above data shows that the agent of the present invention works without the need for prolonged temperature controlled maturation unlike a number of known methods. The quality of the product does improve with maturation but is not an essential feature to obtain the desired product.

Example 11

The composition of Example 2 was wrapped in metallized foil and found to be easy to unwrap and not lose logo definition when kept at the temperatures set out in the above tables. Reference Example 1 was found to melt and become difficult to unwrap.