Process and product produced by the process
A process for producing chocolate or a chocolate-like product comprises: (i) forming a first mixture comprising components of the chocolate or chocolate-like product; (ii) grinding the first mixture in first grinding means; (iii) forming a second mixture comprising components of the chocolate or chocolate-like product; (iv) grinding the second mixture in second grinding means different from the first grinding means; (v) combining the first and second mixtures to form a third mixture; and (vi) conching the third mixture to form the chocolate or chocolate-like product.
1. Process for producing chocolate or a chocolate-like product comprising:
(i) forming a first mixture comprising components of the chocolate or chocolate-like product;
(ii) grinding the first mixture in first grinding means;
(iii) forming a second mixture comprising components of the chocolate or chocolate-like product;
(iv) grinding the second mixture in second grinding means different from the first grinding means;
(v) combining the first and second mixtures to form a third mixture;
(vi) homogenizing the third mixture with a fat; and
(vii) conching the homogenized third mixture to form the chocolate or chocolate-like product.
2. Process according to claim 1 , wherein the first grinding means comprises a roller refiner.
3. Process according to claim 2 , wherein the roller refiner comprises a five roller refiner.
4. Process according to claim 1 , wherein the second mixture is ground to a particle size of less than 80 μm.
5. Process according to claim 1 , wherein the second grinding means comprises a classifier mill.
6. Process as claimed in claim 5 , wherein the classifier mill is an air classifier mill.
7. Process according to claim 1 , wherein the components are selected from the group consisting of cocoa materials, sugars, sugar substitutes, milk powders, fat and mixtures thereof.
8. Process according to claim 7 , wherein the cocoa materials are selected from cocoa powder, cocoa mass, and mixtures thereof.
9. Process according to claim 7 , wherein the milk powders are selected from skimmed milk powder, whey powder, derivatives of whey powder, full cream milk powder and mixtures thereof.
10. Process according to claim 7 , wherein the sugars are selected from sucrose, fructose, glucose, dextrose and mixtures thereof.
11. Process according to claim 7 , wherein the sugar substitutes are selected from inulin, dextrin, isomaltulose, polydextrose, maltitol and mixtures thereof.
12. Process according to claim 1 , wherein the first mixture constitutes from 20 to 65% by weight of the chocolate or chocolate-like product.
13. Process according to claim 1 , wherein the particle size of the second mixture is less than 50 μm.
14. Process according to claim 1 , wherein the second mixture comprises at least 50% by weight of sugar, up to 5% by weight of milk powder and up to 5% by weight of cocoa material based on the total weight of the second mixture.
15. Process according to claim 1 , wherein the level of fat present in the second mixture is less than 12% by weight by weight based on the total weight of the second mixture.
16. Process according to claim 1 , wherein the third mixture is homogenized using a rotor/stator homogenizer.
17. Process according to claim 1 , wherein the third mixture is homogenized such that a temperature rise of at least 10° C. is achieved in the mixture by mechanical input.
18. Process according to claim 1 , wherein the homogenization is carried out to give a mixture with a hardness similar to the hardness resulting the shear from at least two hour of traditional conching in a double or single shaft conche.
19. Process according to claim 18 , wherein the fat in the homogenizing step is selected from the group consisting of cocoa butter, cocoa butter equivalents, butter fat or fractions thereof, palm oil or fractions thereof, coconut or fractions thereof, palm kernel oil or fractions thereof, liquid vegetable oils, interesterified mixtures of the above fats or fractions or hardened components thereof, or mixtures thereof.
20. Process according to claim 1 , wherein the conching is carried out using a three shaft shear conch or a one shaft plough shear conch.
21. Process according to claim 1 , wherein the conching is carried out at temperature from 50 to 100° C.
22. Process according to claim 1 , wherein the conching is carried out for less than 8 hours.
23. Process according to claim 1 , wherein one or more components selected from fat, emulsifiers, flavouring agents and mixtures thereof are added to the mixture in the conch.
24. Process according to claim 23 , wherein the fats that are added to the conch are selected from the group consisting of: cocoa butter, cocoa butter equivalents, butter fat or fractions thereof, palm oil or fractions thereof, coconut or fractions thereof, palm kernel oil or fractions thereof, liquid vegetable oils, interesterified mixtures of the above fats or fractions or hardened components thereof; and mixtures thereof.
25. Process according to claim 23 , wherein the emulsifiers that are added to the conch are selected from the group consisting of lecithin, fractionated lecithin and PGPR or mixtures thereof.
26. Process according to claim 23 , wherein the flavouring agents that are added to the conch are selected from the group consisting of vanilla and caramel or mixtures thereof.
27. Process according to claim 1 , wherein the weight ratio of the fat in the first mixture to the fat in the second mixture is in the range of from 5:1 to 100:1.
28. Process according to claim 1 , wherein the weight ratio of the (fat in the first mixture) : (the fat in the second mixture) : (the fat added after (iv)) is (40 to 60):(0.5 to 2):(40 to 60), based on the weight of the fat in the product of (vi).