Patent Application
20080248174
This invention relates to a process for the coating of food-grade confectionery products, including hard, soft or chewy sweets or sweets made using chocolate. In particular the invention relates to a milk-based coating which is soft and white.
The soft coating comprises a coating applied to some confectionery products, for example sweets, in particular externally to the “cores” or “centres” of the confectionery products, by covering or coating such cores or centres with a solution mainly comprising carbohydrates in which water is bound through the progressive addition of crystalline or powdered sugar. Generally the carbohydrates in solution are in the form of monosaccharides, disaccharides, oligosaccharides and polysaccharides, as such or as mixtures.
The process for coating the centres generally comprises a step of heating the components constituting the syrup, a step of immersing the centres in the heated syrup, an intermediate drying step, normally effected using sugar dusting, followed by final steps of smoothing and polishing to protect the product and render it more attractive.
In order to obtain high quality soft coatings the type and particle size of the sugar and the centre used are governing factors, together with the type of the confectionery syrup used, the characteristics of which affect the process and determine the uniformity of the coating.
In a process for the manufacture of soft confectionery, these variables are therefore taken into consideration right from the first steps of preparation, which essentially comprise preparation of the coating syrup and pre-treatment of the centre. Once the two steps of preparation and pre-treatment had been completed, the process of coating generally takes place in containers of a hemispherical or cylindrical shape, made of copper or stainless steel, which can suitably rotate about an inclined axis, known as pans. In these, once the centres have been loaded in, the coating syrup is added in an amount such as to cover and wet their entire surface area and the procedure then comprises repetitive coating cycles alternating with steps of drying (also known as dewatering) with sugar. This cycle of operations is repeated a certain number of times, usually until the product has achieved the desired size or weight.
In order to obtain a soft coating based on milk, the number of variables, which has to be considered in the coating process, increases, because milk is subject to the problem of browning due to the occurrence of the Maillard reaction, which imparts a dark colour to the coating, under particular temperature conditions. Thus preparation of the milk-based coating syrup and the coating procedure must meet two different requirements at the same time: on the one hand they must avoid the conditions which might give rise to browning of the coating, and on the other hand they must make it possible to easily obtain a soft coating for the centres of the confectionery products, in particular on an industrial scale, where process continuity typically does not permit interruptions for changes or adjustments in the course of production.
Thus in order to manufacture a soft milk-based coating which is still white in colour the known coating process must be suitably modified.
The object of this invention is therefore to provide a soft milk-based confectionery product which will manifestly suggest the ingredient which it contains.
Another object of this invention is to provide a process which is suitable for obtaining a soft white coating on an industrial scale.
These objects are accomplished through the process specified in claim 1.
The invention therefore relates to a process for the manufacture of a confectionery product based on milk, which is soft and white and has a hard, soft or chewy centre, and therefore to the manufacture of confectionery products coated with soft white coatings, comprising the steps of:
a) preparing a coating mixture and loading the centres into a suitable container,
b) coating the centres with the coating mixture prepared in step a),
c) drying the centres so coated,
d) repeating steps b) and c) a sufficient number of times necessary to achieve the desired size for the final coating, characterised in that the coating mixture in step a) comprises milk or a milk derivative and a syrup of one or more carbohydrates selected from the group consisting of glucose, glucose-fructose and sorbitol, the said coating mixture being held within a temperature range from approximately 50 to approximately 64° C. for a time of less than approximately 40 minutes in the course of step a).
Further features and advantages of the invention will be apparent from the following detailed description with reference to an embodiment and the results of tests to evaluate browning and the coating obtained. These examples and tests are provided purely by way of example and without restriction.
In accordance with the invention it has been possible to obtain soft white milk-based coatings for confectionery products on an industrial scale through the inventive selection of coating ingredients and treatment conditions prior to the step of applying the coating to the centres. In fact it has been surprisingly found out that the coating mixture according to the invention is easily deposited on the centres when maintained at a temperature within the temperature range from approximately 50 to approximately 64° C. for a period of less than approximately 40 minutes, owing to the achievement of a suitable viscosity index without initiating the Maillard reaction.
The coating mixture in step a) is preferably held at a temperature of between approximately 54° C. and approximately 60° C. for a time of less than approximately 30 minutes, even more preferably at 58° C.
The viscosity of the coating mixture at the end of preparation step a) will preferably be between 1 and 8 Poise, preferably between 1 and 6.
The confectionery product according to the invention will preferably be a hard, soft or chewy sweet. The centres which have to be coated according to the invention may be jelly or chocolate centres.
According to a preferred embodiment the product in step d) is allowed to dry out in a conditioned environment (15-20° C. and 50-60% relative humidity, R.H.) for a period of 1-4 days, preferably 3 days, and is then subjected to a step of hot coating.
Through this further hot coating the sweets are protected by a thin layer which is resistant to the mechanical stresses of subsequent movements, in addition to ensuring better palatability through the removal of surface roughness.
The said hot coating is preferably achieved using a further coating mixture comprising sugar, water and glucose syrup in one or more application cycles, drying with air at temperatures over 25° C. Even more preferably drying is carried out at a temperature of approximately 35° C.
The coating mixture according to the invention comprises milk or a milk derivative. When the term milk or a milk derivative is used, this means one or more compounds selected from the group consisting of skimmed milk, partly skimmed milk, whole milk, partly skimmed condensed milk, skimmed condensed milk, concentrated sweetened milk, yoghurt.
In a first embodiment of the invention the coating mixture in step a) comprises sweetened partly skimmed condensed milk, water and glucose-fructose syrup, comprising in turn glucose and fructose in the form of mono-, oligo- and polysaccharides. Preferably the fructose in the glucose-fructose syrup is present in an amount within the range between 5 and 20% by weight with respect to the weight of the glucose-fructose syrup.
In a second and preferred embodiment of the invention the coating mixture in step a) comprises partly skimmed milk and liquid sorbitol. More preferably the liquid sorbitol contains sorbitol in an amount of approximately 50% with respect to the mass of the liquid sorbitol.
In accordance with the invention the prepared centres are then coated with the coating mixture in suitable containers, for example pans.
After the centres have been coated in step b), dispersing agents are then added which make it possible to dry out the centres (step c)). These dispersing agents are edible materials, preferably in powder form. More preferably the dispersing agent is powdered milk. Advantageously, in one embodiment of the invention, after drying with a first dispersing agent a step of drying with dextrose may be performed and this makes it possible to avoid agglomeration phenomena and obtain an even more uniform coating.
In accordance with the invention steps b) and c) are repeated the number of times necessary to achieve a suitable size for the final coating, as known to those skilled in the field of confectionery. Preferably, according to the invention, the last drying step is performed using sugar syrup, i.e. comprising glucose, sugar and water. Even more preferably, in order to obtain a smooth and regular surface the last drying step is carried out with icing sugar, by which term is meant a sugar having a particle size in which at least 95% of the particles are smaller than 250 μm.
As is known to those skilled in the art of confectionery, additives, for example flavouring and/or colouring agents and/or juices of plant origin, may be added to the coating mixture or directly to the pan. Thus in accordance with the invention these substances are preferably added to the coating syrup before coating the hard, soft or chewy centres in step a) of the process.
In a further aspect the invention also relates to a soft coating comprising a milk content of more than 20% as indicated in claim 19.
The soft milk-based coating according to the invention will advantageously have a white appearance.
The invention will now be described in greater detail with reference to a number of embodiments which are provided purely by way of indication and without restriction.
All the percentages are percentages by weight. In the process—percentages by weight in relation to the weight of the total mass, and in the final isweet—percentages by weight in relation to the weight of the sweet obtained. Whenever the term “° Bx” is used this means “degrees Brix”, corresponding to the sugar content from determination of the optical activity of n grams of sugar in 100 grams of solution at 20° C.
A sweet of the jelly type based on pectin was prepared using the conventional method of casting into starch as a soft centre for coating according to the invention.
The base syrup for the jelly was obtained by mixing 33 kg of pectin solution (held at a temperature of 95° C.), 63 kg of D.E. 60 glucose syrup and 57 kg of sugar in bags in a hot (warmix) mixer. The mixture was cooked until the residual refractometer reading was 83° Bx (corresponding to a temperature of 103° C.) and then acidified with a 25% solution of citric acid. Before the casting step 3.5 kg of sweetened concentrated partly skimmed milk, together with if appropriate additional substances such as flavourings, colouring agents and juices of plant origin, were added to the 100 kg of cooked syrup. The solution was then poured into the starch moulds at a temperature of 84° C. corresponding to 77° Bx. Subsequently the normal drying operations were carried out (to a final dry residue of 86° Bx), demoulding and sugaring were performed, as is characteristic of the process for the production of gelatine.
A milk-based coating mixture was prepared by mixing 6.4 kg of sweetened condensed partly skimmed milk (refractomer residue 73° Bx) with ii6.4 kg of glucose-fructose syrup, 1.2 kg of water and finally 10 g of milk flavour in a stainless steel container. The said glucose-fructose syrup contained glucose in an amount of approximately 22% and fructose in an amount of 18% with respect to the mass of glucose-fructose syrup (refractometer residue 80° Bx). The final mixture had a dry residue of 73° Bx and was held at a temperature of 58° C. for a time of not more than 30 minutes by heating it in a water bath, thus ensuring that not only the characteristic white colour of the milk but also the viscosity necessary for the distribution operations in the pan were preserved.
Steps b)-d): Coating and Drying of the Centres
20 kg of sugar-coated centres prepared as indicated above were placed in a copper pan. The first coating consisted of adding of 1.5 kg of the milk-based coating mixture in step a) sufficient to guarantee coating of the entire surface area of the centres. When these were uniformly wetted and sticky 0.65 kg of powdered skimmed milk were distributed in order to dry off the surface.
While the product continued to rotate in the pan 0.25 kg of dextrose were then added and this contributed to final absorption of the moisture in the syrups.
The steps of coating in a pan and subsequent drying were then carried out for a further 16 cycles, using the same ingredients as in the first coating cycle in sequence in the following amounts: 0.8 kg of the milk-based coating mixture, 1.2 kg of powdered skimmed milk, 0.25 kg of dextrose. In order to prepare the surfaces of the coated products for the polishing step the final coating was carried out using 1.2 kg of sugar syrup (comprising D.E. 38 glucose syrup, sugar, water) and subsequently adding 3 kg of powdered sugar. The surfaces of the jellies coated in this way were smooth, regular and white in colour.
The coated sweets weighed approximately 3.4 g, subdivided into 68% coating and 32% centre, and had a white coating with a milk content of 61% (42% of the finished sweet).
In order to improve the coating properties the jellies coated in step b) and c) were left to dry in an air-conditioned atmosphere for three days before applying the final hot coating.
The latter was applied using a coating mixture of 71° Bx comprising 70% sugar, 26% water and 4% D.E. 38 glucose syrup.
Thus 6 kg of mixture subdivided into eight coating cycles, with drying with hot air at 35° C., were distributed over the cold-coated and dried product.
25 kg of jelly centres prepared as in Example 1 were subjected to the coating process according to the invention.
A milk-based coating mixture was prepared by mixing 6.4 kg of sweetened condensed partly skimmed milk (refractometer residue 73° Bx) with 6.4 kg of glucose-fructose syrup, 1.2 kg of water and finally 10 g of milk flavour in a stainless steel container. The said glucose-fructose syrup comprised glucose in an amount of approximately 40% and fructose in an amount of 42% (refractometer residue 71° Bx). The final mixture had a dry residue of 73° Bx and was held at a temperature of 54° C. for a time not exceeding 30 minutes, heating it in a water bath, thus ensuring that both the characteristic white colour of the milk and the viscosity necessary for the distribution operations in the pan were preserved.
Steps b)-d): Coating and Drying of the Centres
25 kg of sugared centres prepared as indicated above were loaded into a copper pan. The first coating consisted of adding of 1.5 kg of the milk-based coating mixture in step a), sufficient to ensure that the entire surface area of the centres was coated. When these were uniformly wetted and sticky, 0.65 kg of powdered skimmed milk was distributed in order to dry their surfaces.
While the product continued to rotate in the pan 0.25 kg of dextrose were then added and this contributed to final absorption of the moisture in the syrups.
The steps of coating in a pan and subsequent drying were then carried out for a further 16 cycles, using the same ingredients as in the first coating cycle in sequence in the following amounts: 0.8 kg of milk-based coating mixture, 1.2 kg of powdered skimmed milk and 0.25 kg of dextrose. In order to prepare the surfaces of the coated products for the polishing step, the final coating was carried out using 1.2 kg of sugar syrup (comprising D.E. 38 glucose syrup, sugar, water) and subsequently adding 3 kg of powdered sugar. The surface of the jellies coated in this way was smooth, regular and white in colour.
The coated sweets weighed approximately 3.6 g, subdivided into 63% coating and 37% centre, and had a white coating with a milk content of 62% (39% of the finished sweet).
30 kg of jelly centres prepared as in example 1 were subjected to the coating process according to the invention.
A milk-based coating mixture was prepared by mixing 6.4 kg of sweetened condensed partly skimmed milk (refractometer residue 73° Bx) with 6.4 kg of glucose-fructose syrup, 1.2 kg of water and finally 15 g of milk flavour in a stainless steel container. The said glucose-fructose syrup included fructose in an amount of 9% in relation to the mass of glucose-fructose syrup (refractometer residue 80° Bx). The final mixture had a dry residue of 73° Bx and was held at a temperature of 60° C. for a period of 24 minutes, heating it in a water bath, thus ensuring that both the characteristic white colour of the milk and the viscosity necessary for the subsequent distribution operations in the pan were preserved.
Steps b)-d): Coating and Drying of the Centres
30 kg of sugared centres prepared as indicated above were loaded into a copper pan. The first coating consisted of adding 1.5 kg of the milk-based coating mixture in step a) sufficient to ensure covering of the entire surface area of the centres. When these were uniformly wetted and sticky 0.65 kg of powdered skimmed milk were distributed in order to dry their surfaces.
While the product continued to rotate in the pan 0.25 kg of dextrose were then added and this contributed to final absorption of the moisture in the syrups.
The steps of coating in a pan and subsequent drying were then carried out for a further 16 cycles, using the same ingredients as in the first coating cycle in sequence in the following amounts: 0.8 kg of milk-based coating mixture, 1.2 kg of powdered skimmed milk, 0.25 kg of dextrose. In order to prepare the surfaces of the coated products for the polishing step the last coating was carried out using 1.2 kg of sugar syrup (comprising D.E. 38 glucose syrup, sugar, water) and subsequently adding 3 kg of powdered sugar. The surfaces of the jellies coated in this way were smooth, regular and white in colour.
The coated sweets weighed approximately 3.9 g, subdivided into 59% coating and 41% centre, and had a white coating with a milk content of 61% (36% on the finished sweet).
30 kg of jelly centres prepared as in Example 1 were subjected to the coating process according to the invention.
A milk-based coating mixture was prepared by mixing 6.4 kg of sweetened condensed partly skimmed milk (refractometer residue 73° Bx) with 6.4 kg of liquid sorbitol, 1.2 kg of water and finally 20 g of milk flavour in a stainless steel container. The said liquid sorbitol comprised sorbitol in an amount of approximately 50% by mass (refractometer residue 70° Bx). The final mixture had a dry residue of 73° Bx and was held at a temperature of 53° C. for a time of approximately 35 minutes, heating it in a water bath, thus ensuring that both the characteristic white colour of the milk and the viscosity necessary for the distribution operations in the pan were preserved.
Steps b)-d): Coating and Drying of the Centres
30 kg of sugared centres prepared as indicated above were loaded into a copper pan. The first coating consisted of adding 1.5 kg of the milk-based coating mixture in step a) sufficient to ensure that the entire surface area of the centres was covered. When these were uniformly wetted and sticky 0.5 kg of powdered skimmed milk were distributed in order to dry their surfaces.
While the product continued to rotate in the pan 0.25 kg of dextrose were added and this contributed to final absorption of the moisture in the syrups.
The steps of coating in a pan and subsequent drying were then carried out for a further 16 cycles, using the same ingredients as in the first coating cycle in sequence in the following amounts: 0.8 kg of the milk-based coating mixture, 1.1 kg of powdered skimmed milk and 0.25 kg of dextrose. In order to prepare the surface of the coated products for the polishing step the last coating was carried out using 1.2 kg of sugar syrup (comprising D.E. 38 glucose syrup, sugar, water) and subsequently adding 3 kg of powdered sugar. The surfaces of the jellies coated in this way were smooth, regular and white in colour.
The coated sweets weighed approximately 3.9 g, subdivided into 59% coating and 41% centre, and had a white coating with a milk content of 57% (34% of the finished sweet).
30 kg of jelly centres prepared as in Example 1 were subjected to the coating process according to the invention.
A milk-based coating mixture was prepared mixing 6.4 kg of sweetened condensed partly skimmed milk (refractometer residue 73° Bx) with 4.3 kg of liquid sorbitol and 2.1 kg of D.E. 38 glucose syrup, 1.2 kg of water and 15 g of milk flavour in a stainless steel container. The said liquid sorbitol included sorbitol in an amount of approximately 50% by mass (refractometer residue 70° Bx). The final mixture had a dry residue of 73° Bx and was held at a temperature of 58° C. for a time of 30 minutes, heating in a water bath, thus ensuring that both the characteristic white colour of the milk and the viscosity necessary for the distribution operations in the pan were preserved.
Steps b)-d) Coating and Drying of the Centres
30 kg of sugared centres prepared as indicated above were loaded into a copper pan. The first coating consisted of adding 1.5 kg of the milk-based coating mixture in step a) sufficient to ensure that the entire surface area of the centres was covered. When these were uniformly wetted and sticky 0.65 kg of powdered skimmed milk were distributed in order to dry their surfaces.
While the product continued to rotate in the pan 0.25 kg of dextrose were then added and this contributed to final absorption of the moisture in the syrups.
The steps of coating in a pan and subsequent drying were then carried out for a further 16 cycles, using the same ingredients as in the first coating cycle in sequence in the following amounts: 0.8 kg of milk-based coating mixture, 1.2 kg of powdered skimmed milk and 0.25 kg of dextrose. In order to prepare the surfaces of the coated products for the polishing step the final coating was applied using 1.2 kg of sugar syrup (comprising D.E. 38 glucose syrup, sugar, water) and subsequently adding 3 kg of powdered sugar. The surfaces of the jellies coated in this way were smooth, regular and white in colour.
The coated sweets weighed approximately 3.9 g, subdivided into 59% coating and 41% centre, and had a white coating with a milk content of 61% (36% of the finished sweet).
30 kg of fondant chocolate centres were subjected to the gumming process which provided for the following steps: A solution of 5 kg of water and 12 kg of sugar was prepared and brought to the boil. A mixture of 4 kg of gum Arabic and 6 kg of water were then added, producing a final solid residue of 60° Bx and a temperature of 65° C. 30 kg of chocolate centres were then coated (gummed) with 1 kg of gumming solution and dried with 7.3 kg of icing sugar.
A milk-based coating mixture was prepared by mixing 6.4 kg of sweetened condensed partly skimmed milk (refractometer residue 73° Bx) with 4.3 kg of liquid sorbitol and 2.1 kg of D.E. 38 glucose syrup, 1.2 kg of water and 15 g of milk flavour in a stainless steel container. The said liquid sorbitol comprised sorbitol in an amount of approximately 50% by mass (refractometer residue 70° Bx). The final mixture had a dry residue of 73° Bx and was held at a temperature of 58° C. for a time of 30 minutes, heating in a water bath, thus ensuring that both the characteristic white colour of the milk and the viscosity necessary for the distribution operations in the pan were preserved.
Steps b)-d): Coating and Drying of the Centres
30 kg of sugared centres prepared as indicated above were loaded into a copper pan. The first coating consisted of adding 1.5 kg of the milk-based coating mixture in step a), sufficient to ensure that the entire surface area of the centres was coated. When these were uniformly wetted and sticky 0.65 kg of powdered skimmed milk were distributed in order to dry their surfaces.
While the product continued to rotate in the pan 0.25 kg of dextrose were then added and this contributed to final absorption of the moisture in the syrups.
The steps of coating in a pan and subsequent drying were then carried out for a further 16 cycles, using the same ingredients as in the first coating cycle in sequence in the following amounts: 0.8 kg of milk-based coating mixture, 1.2 kg of powdered skimmed milk and 0.25 kg of dextrose. In order to prepare the surfaces of the coated products for the polishing step the final coating was carried out using 1.2 kg of sugar syrup (comprising D.E. 38 glucose syrup, sugar, water) and subsequently adding 3 kg of powdered sugar. The surfaces of the chocolate centres coated in this way were smooth, regular and white in colour.
The coated chocolate confectionery weighed approximately 2.65 g, subdivided into 63% coating and 37% centre, and had a white coating with a milk content of 62% (39% of the finished sweet).
The milk-coated jellies obtained in Examples 1-5 and the coated chocolate centres in Example 6 were evaluated for softness, degree of whiteness and taste. The samples were evaluated by a panel of 10 persons.
The panel were requested to evaluate the 3 parameters by assigning one of the following scores:
+++++=excellent
++++=good
+++=fair
++=adequate
+=poor
Two Tests were Performed:
Test 1) The 3 parameters were evaluated at three different times: as soon as the sweets had been produced, 6 months after coating and 12 months after coating. The sweets tested were held under uncontrolled environmental conditions: temperature from 10° C. to 30° C. and relative humidity from 25% to 75%.
Test 2) The 3 parameters were evaluated at three different times: as soon as the sweets had been produced, 6 months after coating and 12 months after coating. The sweets tested were held under thermal cycle conditions: a temperature of 30° C. for 2 days alternating with ambient temperature for 2 days.
The results are shown in Tables 1 and 2 below.
As indicated in the tables above, the coated jellies in Example 3 and Example 1 containing fructose in the coating had excellent colour, taste and softness properties when held under uncontrolled environmental conditions and good colour and softness and excellent taste characteristics when subjected to thermal cycling, even 6 months after coating.
The coating mixtures in Examples 1, 2, 3, 4 and 5 and 6 were subjected to 70° C. and an evaluation was made to determine how long it took for the mixtures to brown. In all cases the mixtures became brown immediately preventing subsequent steps of coating.
Stability test on milk-based coating syrups at a temperature of 70° C.
To demonstrate that selection of the coating ingredients is inventive the following three coating mixtures were prepared at temperatures and over times suitable for avoiding browning of the milk.
50 g of mixture comprising:
sweetened partly skimmed milk, 5% fat=45.7%
glucose-fructose syrup containing 18% of fructose (D.E. 70)=45.7%
water=8.6%
were prepared in a glass beaker.
Preparation and heating of the mixture as for mixture 1, but using a glucose-fructose syrup with a high fructose content, specifically comprising 42% of fructose (D.E. 95).
Preparation and heating of a mixture as for mixtures 1 and 2, but using a glucose syrup comprising 50% maltose (D.E. 42).
The mixtures were separately heated in a water bath to temperatures of 56° C. After 35 minutes heating the mixtures were white and the viscosity of the solutions was evaluated. The values shown in Table 3 were obtained.
Although all three mixtures were white in colour, after 35 minutes heating coating Mixture 3 had a viscosity which was too high to permit coating in the subsequent coating step. Conversely Mixtures 1 and 2 according to the invention reached a viscosity which was suitable for the subsequent step of coating the centres without any browning occurring.
The temperature of Mixture 3 was therefore further raised to reduce the viscosity. After 22 minutes of treatment at 70° C. the mixture began to brown and the viscosity was still too high to permit uniform coating of the centres.
It is therefore obvious that the choice of ingredients according to the invention and the time periods and temperatures make it easy to prepare a soft white coating for confectionery products. Definition of the parameters indicated in the appended claims therefore makes coating possible on an industrial scale, where it is necessary to have continuity of production of the coated confectionery product without the occurrence of interruptions, which would otherwise drastically reduce the efficiency of the industrial process.
Although the invention has been described with reference to soft jelly centres and chocolate centres, the general technique may allow for changes or supplements to the procedure just described in order that it may be applied to other types of confectionery product, deriving the surprising properties according to the invention from the nature of the step of preparing the coating mixture as indicated in the appended claims.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IT2005/000555 | 9/27/2005 | WO | 00 | 3/20/2008 |
