Technical Field of the Invention

The invention relates to a filled chocolate with whole cherry particles and fluid fruit syrup and production method thereof. Main feature of the invention is that it is a production method enabling the cherry particle to hold within the chocolate such that it will not damage to the bottom shell of the chocolate by not emerging onto the fluid filling.

State of the Art

4000 years ago, Honduras inhabitants realized a discovery affecting the whole world and produced a beverage from cocoa seeds. By this new development, they discovered chocolate having an important place in our lives in today’s world, as well as finding a new taste.

Etymologists state that the word“chocolate” roots from the Aztec word“xocolatl”, and “atl” part of the word means “water” or “beverage”. There are three different explanations for“Xocol” part; there are etymologists defining that it was used with the meaning of “bitter” or “hot”, along with the ones who think that it means “noise” because it is ground in the mortar in a noisy manner.

Chocolate started to be used as a cold and bitter beverage and consumed as“bitter beverage” in special days and religious ceremonies. Aztecs and Mayas not only enjoyed this taste for ages, but also provided the cocoa with a leading role in trade. Chocolate was noticed during the exploration trips of Christopher Columbus and it was spread around the Europe and then around the world in 16th century by the Spanish.

Arrival of cocoa to the Europe has become the start of a new era for chocolate. Having a bitter taste, cocoa has been flavored with various flavors and fillings, particularly sugar. One of the said fillings is viscous fillings including whole fruit particles and syrups introduced into the chocolate. In the prior art, cherry particles being one of the fruits which has been used as fillings in the chocolate are hardened by keeping in the powdered sugar. After adequately hardening the fruits, invertase enzyme is sprayed on them and their tops are covered by chocolate. The enzyme functions over time, liquefies sugar by digesting and a product is obtained with fluid filling and cherry particles. However, the shape of the products obtained by this method has a dispersed structure and it is not possible to produce chocolate with the preferred form.

In the prior art, many patents are present about filled chocolate and production technologies thereof. Any patent has not been encountered about production of filled chocolate with syrup and fruit particles having uniform shape and not deforming over time by the method used for said filled chocolate with fruit particles and fruit syrup, used in the said production method and the development of the production method by Frozen Cone technology.

In European Patent No. EP2543258 A1 , “Frozen Cone” and “Cold Stamping” technologies are described to be used in producing filled chocolate. In said patent, production of candy products with different thicknesses and filling proportions, with a single molding model and cap. However, the cherry and any fruit having the particle shape have not been mentioned in said patent.

In China Patent No. CN103988966, a chocolate product is mentioned having large fruit particles. Fruit particle is covered by chocolate in this invention. The fruit which is covered by chocolate is located into the chocolate shell, and then rear shell is closed. In said patent, the fruit will not move in the shell chocolate because the outer portion of it is hardened, also the effect of the juice and fruit will not be perceived properly.

In China Patent No. CN204409480, three-layer chocolate structure and its production are mentioned: There is fruit pulp in the internal layer and bitter chocolate above, and its top is covered by sugar. The chocolate of said patent is a product suitable for people having diabetes, which has high sweetness and low calorie. However, any fruit having the particle shape and its production method has not been mentioned in said patent. In China Patent No. CN 1633870, the production method is mentioned for a filled chocolate having two-layer heart shape. The product obtained after the process consists of chocolate and fruit candy with preservative. Here, fruit candy having particle structure and agar mixture are applied into a heart-shaped form, the chocolate is heated up to the range of 60-80 C° and also stirred. Then, it is cooled down to 30-40 C°. This candy which was obtained with heart shape is located into a cooled mold into which a thin layer of chocolate is poured, cooled and packaged. In the product which was produced by said method and in said patent, any fruit having particle structure within a fluid fruit syrup and chocolate shell which is filled were not mentioned.

In Russia Patent No. RU 2103878C1 , preparation method for cherry candy as chocolate was mentioned. An anti-crystallization-stabilizer agent was added in the range of 0.05-0.5% in order to realize filling. The surfaces of fruits impregnated with alcohol is covered by a protective layer, which protective layer comprises protein or hydrocarbon additive. Though said candy is a durable product whose shelf life is extended to 4 months, cherry or any fruit in the particle form and being in a fruit syrup, and chocolate shell was not mentioned in the said patent.

Filled chocolate and candy production methods and the products produced by said methods were mentioned, but a durable product and production method were not mentioned for fruit particles within the similar fruit syrup and chocolate shell, in said patents.

Technical Problems Aimed by the Invention to be solved

In the production method of filled chocolate of the invention, it is aimed to produce new products with filling for the candy sector by compounding filled chocolate products with filling, syrup and fruit particles in different molds through “Frozen Cone” and “Cold Stamping” technologies. In the production method for fruit syrup and chocolate with whole fruits, whole fruit is located in the chocolate shell obtained with a smooth and definite pattern by using“Frozen Cone” and“Cold Stamping” technology while it is still in the mold where it is formed, then chocolate is added on top of it and the whole filling is enclosed in the shell. In the prior art, cherry particles being one of the fruits which has been used as fillings in the chocolate are hardened by keeping in the powdered sugar. After adequately hardening the fruits, invertase enzyme is sprayed on them and their tops are covered by chocolate. The enzyme functions over time, liquefies sugar by digesting and a product is obtained with fluid filling and cherry particles. However, the shape of the products obtained by this method has a dispersed structure and it is not possible to produce chocolate with the preferred form.

In the prior art, the problem which was overcome in the development of the invention is related to closing the top of the chocolate shell thoroughly by enabling the fruit which is placed within the shell made of chocolate and whose density is low to be enclosed in the denser syrup. Thus, the product can be produced with whole fruit and leakage and outflow of the filling is prevented during the shelf life.

The first advantage of the method of the invention is that it allows for producing products with fruit syrup and fruit particle within 100% chocolate shell and which is not deformed during the shelf life, which is not provided in the filled chocolates previously produced by“Frozen Cone” and“Cold Stamping” methods.

Another advantage of the method of the invention is that it is a production method to prevent leakage and outflow of the fruit syrup, being the filling substance in the chocolate, during the shelf life.

Storage conditions are the parameters directly affecting the product quality for the foods having low humidity content such as chocolate and the products comprising chocolate. In the prior art, deformation of the filled chocolate has not been mentioned according to its storage conditions. Production of the products having long shelf lives will be enabled by the production method of the invention.

Figures will be used for better understanding the method of the invention and the product which is produced.

Description of the Drawings Figure 1 : It is the cross-sectional view illustrating syrup and fruit sections in the shell and filling parts of the filled chocolate which was produced by the method of the invention.

Figure 2: It is a perspective view illustrating the exemplary mold in which the shell portion of the filled chocolate produced by the method of the invention.

Figure 3: It is the perspective view illustrating the process of placing fruit particle and adding fruit syrup within the shell portion of the filled chocolate produced by the method of the invention.

Figure 4: It is the flow chart of the production of the filled chocolate produced by the method of the invention.

Reference Numerals of the Sections and Parts to Serve for Describing the Invention

1- Chocolate outer shell

1a- Chocolate lower shell

2- Internal filling substance-fruit syrup

2a- Syrup top shell

3- Fruit particle-cherry

4- Chocolate

5- Filled chocolate

6- Mold cap

7- Mold Stages of the method of the invention;

Depositing chocolate into the mold (210)

Shell formation (220)

Placing fruit particle within the shell (230)

- Passing through cooling tunnel (240)

Depositing fruit syrup (250)

Passing through cooling tunnel (260)

Closing obtained chocolate shell (270)

Passing through cooling tunnel (280)

Receiving from the mold and packaging (290) Detailed Description of the Invention

In the production method for fruit particle and chocolate with fruit syrup filling of the invention, it is aimed to produce new products for the chocolate sector by compounding chocolate products with filling or syrups in different molds and to develop said production methods through“Frozen Cone” and“Cold Stamping” technologies. In the prior art, production technologies for filled chocolate products in the market relies upon mold-turning technique. The method of the invention allows for the filing to be prepared with fruit particle and fruit syrup to be durable and for producing the filled product in which the fruit particle is immobilized on the peak point of the shell and does not change place with syrup due to the density difference, thus which product does not deform due to the similar reasons during the shelf life.

Chocolate outer shell (1 ) portion and internal filling substance-fruit syrup (2) and fruit particle-cherry (3) portion within the fruit syrup are presented in Figure 1 as cross- sectional view, showing the structure of the filled chocolate (5) product produced by the method of the invention. Semi-finished fluid chocolate (4) included in Figure 2 and deposited into the mold (7) are shaped as an outer shell (1 ) with a thin layer. Production of the chocolate outer shell (1 ) such that no leakage occurs from the inside is illustratively presented in Figure 2 step by step. Then, preferred fruit particle-cherry (3) is placed in said chocolate outer shell (1 ) and internal filling substance-fruit syrup (2) is added on top. Said internal filling substance-fruit syrup (2) is covered by the chocolate (4) in a fluid state and the process of enclosing the whole filling by chocolate outer shell (1 ) layer is completed.

Production of said filled chocolate (5) is enabled by placing fruit particle-cherry (3) and internal filling substance-fruit syrup (2) into the chocolate outer shell (1 ) and by passing it through cooling units subsequently, in the developed method of the invention. Main process steps for filled chocolate (5) production are defined in the flow chart of the process in Figure 4.

Fluid chocolate (4) has the suitable viscosity and temperature values for expanding over the surface of the mold (7), in the developed production method of the invention. Said fluid chocolate (4) is deposited into the mold (7) in the required amount and frozen mold cap (6) enters into said fluid chocolate (4) having the temperature varying from - 10 to -20 °C by using“Frozen Cone Technology” or“Cold Stamping Technology” and it spreads the chocolate (4) throughout the surface of the mold (7). Thus, a thin chocolate outer shell (1 ) having a uniform thickness takes the shape of the mold. It is an important condition that this chocolate outer shell (1 ) formed takes the shape of the mold, and also it has the viscosity to adhere fruit particle-cherry (3) to itself.

In the developed production method of the invention, after the process of chocolate outer shell (1 ) formation, fruit particles-cherry (3) is placed on the chocolate outer shell (1 ) which took the shape of said mold (7), and then the molds (7) are leaded into the cooling tunnel. In said cooling tunnel, the chocolate (4) which was spread throughout the surface of the mold (7) is completely hardened and fruit particle-cherry (3) completely adheres into the chocolate outer shell (1 ).

Fluid internal filling substance-fruit syrup (2) is deposited onto the chocolate outer shell (1 ) with fruit particles which exited from the cooling tunnel in a temperature within the range of 26-29°C. Deposited internal filling material-fruit syrup (2) should have a temperature not to melt chocolate (4) and not to tail during the depositing process. Also, as long as said internal filling substance-fruit syrup (2) stays in the cooling tunnel, syrup top shell (2a) will be formed above and syrup top shell (2a) portion formed should have the resistance and viscosity to carry the load to arise when forming the chocolate lower shell (1a) to be created ultimately.

If internal filling substance-cherry syrup (2) used is prepared with low viscosity, it may be deposited with low temperatures, it does not melt the chocolate (4) and it will have the feature not to form tailing. However, said internal filling substance-cherry syrup (2) will not have the adequate viscosity during chocolate lower shell (1a) formation at the bottom and it will not have the strength to carry the chocolate (4). As a result, chocolate lower shell (1a) portion at the bottom and internal filling substance-fruit syrup (2) are mixed together, and thus said filing is not enclosed within chocolate. On the other hand, if internal filling substance-fruit syrup (2) is prepared with high viscosity, higher temperatures will be needed to obtain in order to deposit syrup. As a result of introducing internal filling substance-fruit syrup (2) with high temperature on the chocolate (4), chocolate outer shell (1 ) melts and its shape and chocolate temper will be deteriorated. Because of these reasons, syrup brix, prescription components, viscosity value, and syrup temperature are significant variables. After depositing internal filling substance-cherry syrup (2), molds (7) enter into the cooling tunnel again in order to have the strength to carry chocolate lower shell (1 a) portion. The products exiting the cooling tunnel are completely covered by chocolate outer shell (1 ) and chocolate lower shell (1 a) portion is created at the bottom. Molds (7) enter into the cooling tunnel again, in order to enable chocolate (4) constituting the chocolate lower shell (1a) portion at the bottom to be frozen. Filled chocolates (5) being in the state of the end-product after chocolate lower shell (1a) portion is hardened are received by means of the robots and they are laid together on the packaging belt. Packaging is carried out after this stage and the products are transmitted to the end- user.

Filled chocolate production method of the invention through“Frozen Cone” and“Cold Stamping” mainly consists of following stages considering it as a whole process:

Depositing chocolate into the mold (210)

Shell formation (220)

Placing fruit particle within the shell (230)

Passing through cooling tunnel (240)

Depositing fruit syrup (250)

Passing through cooling tunnel (260)

Closing obtained chocolate shell (270)

Passing through cooling tunnel (280)

Receiving from the mold and packaging (290)

The steps of these stages are described below:

Depositing chocolate into the mold (210): In the production method developed, fluid chocolate (4) is deposited into said mold (7) in the predetermined amounts as the first step, when it has the suitable viscosity and temperature values for expanding throughout the surface of the selected mold (7). In the subsequent stage, the process of forming chocolate outer shell (1 ) is performed by cooling down the chocolate (4) which is poured, that is deposited onto the molds by means of “Frozen Cone Technology” or“Cold Stamping Technology”. Shell formation (220): In said production method, frozen mold cap (6) enters into the deposited fluid chocolate (4) having the temperature varying from -10 to -20 °C by using“Frozen Cone Technology” or“cold Stamping Technology” and it spreads the deposited chocolate (4) to cover the internal surface of the mold (7). Thus, a thin chocolate outer shell (1 ) having a uniform thickness takes the shape of the mold (7). It is an important condition that this chocolate outer shell (1 ) formed takes the shape of the mold, and also it has the viscosity to adhere fruit particle-cherry (3) to itself.

In the developed production method of the invention, after the stage of chocolate outer shell (1 ) formation, the process of placing fruit particles-cherry (3) on the chocolate outer shell (1 ) which took the shape of said mold (7).

Placing fruit particle within the shell (230): After the stage of shell formation (220), fruit particles-cherry (3) are placed on the chocolate outer shell (1 ) which took the shape of said mold (7), and then the molds (7) are leaded into the cooling tunnel.

Passing through cooling tunnel (240): After the stage of placing fruit particle within the shell (230), in said cooling tunnel, the chocolate (4) which was spread throughout the surface of the mold (7) is completely hardened and fruit particle-cherry (3) completely adheres into the chocolate outer shell (1 ). After this stage, the stage of depositing internal filling substance-fruit syrup (2) into the chocolate outer shell (1 ) is performed.

Depositing fruit syrup (250): Fluid internal filling substance-fruit syrup (2) having a temperature range of 26-29°C is deposited on the chocolate outer shell (1 ) in which fruit particle-cherry (3) is placed and which exited from the cooling tunnel. Deposited internal filling material-fruit syrup (2) has a temperature not to melt chocolate (4) and not to tail during the depositing process. Then, the molds (7) are leaded into the cooling tunnel again.

Passing through cooling tunnel (260): Also, as long as deposited internal filling substance-fruit syrup (2) stays in the cooling tunnel, syrup top shell (2a) will be formed above and it is of great significance that syrup top shell (2a) portion formed should have the resistance and viscosity to carry the load to arise when forming the chocolate lower shell (1 a) to be created ultimately such that the product produced in the subsequent process has the desired feature and all processes achieve their aims. Closing obtained chocolate shell (270): Chocolate (4) is deposited again on the syrup top shell (2a) portion which is formed on the internal filling substance-fruit syrup (2) after entering into the cooling tunnel. Syrup top shell (2a) portion has an important function which is created before this process ultimately. After this process, internal filling substance-fruit syrup (2) is completely covered by chocolate outer shell (1 ). Cooling process is performed again, after this process.

Passing through cooling tunnel (280): Molds (7) enter into the cooling tunnel again, in order to enable chocolate lower shell (1a) portion has desired strength features. The products exiting the cooling tunnel are completely covered by chocolate outer shell (1 ) having a solid structure and chocolate lower shell (1a) portion is created at the bottom.

Receiving from the mold and packaging (290): Filled chocolates (5) being in the state of the end-product after chocolate lower shell (1a) portion is hardened are received by means of the robots and they are laid together on the packaging belt. Packaging is carried out after this stage and the products are transmitted to the end- user.

Industrial Applicability of the Invention

The production of chocolate and candy products are realized with different raw material and contents by this development obtained through“Frozen Cone Technology” and “Cold Stamping Technology”. The product is deposited to the mold and then it is expanded through the mold with a cold cap, in accordance with said method. Formation of the candies directly with the mold cap without using a mold is possible in accordance with the other methods on which the development obtained by these technologies is applied and the raw material to be used.

Different types of products but chocolate such as caramel and solid candies will be produced with filling by means of the formation-by-cold technologies and the developed method. Along with the fact that water- and oil-based fillings may be provided within the oil-based coating, water- and oil-based cream fillings will be able to be provided within the water-based coating without causing any problem during the shelf life and it will be possible to obtain various filled products, by developing the production method of said product. There are not only chocolate and caramel types included by the definition of the candy, but also water-based products having high sugar content such as solid candies. Selecting the fruit particles and syrup type with different contents creates a wide product range and allows for producing chocolate and other food stuffs with filling having a long shelf life.