Classifications

• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23C—DAIRY PRODUCTS, e.g. MILK, BUTTER OR CHEESE; MILK OR CHEESE SUBSTITUTES; MAKING THEREOF
  • A23C9/00—Milk preparations; Milk powder or milk powder preparations
  • A23C9/152—Milk preparations; Milk powder or milk powder preparations containing additives
  • A23C9/156—Flavoured milk preparations ; Addition of fruits, vegetables, sugars, sugar alcohols or sweeteners
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23C—DAIRY PRODUCTS, e.g. MILK, BUTTER OR CHEESE; MILK OR CHEESE SUBSTITUTES; MAKING THEREOF
  • A23C9/00—Milk preparations; Milk powder or milk powder preparations
  • A23C9/12—Fermented milk preparations; Treatment using microorganisms or enzymes
  • A23C9/13—Fermented milk preparations; Treatment using microorganisms or enzymes using additives
  • A23C9/1307—Milk products or derivatives; Fruit or vegetable juices; Sugars, sugar alcohols, sweeteners; Oligosaccharides; Organic acids or salts thereof or acidifying agents; Flavours, dyes or pigments; Inert or aerosol gases; Carbonation methods
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G1/00—Cocoa; Cocoa products, e.g. chocolate; Substitutes therefor
  • A23G1/30—Cocoa products, e.g. chocolate; Substitutes therefor
  • A23G1/56—Cocoa products, e.g. chocolate; Substitutes therefor making liquid products, e.g. for making chocolate milk drinks and the products for their preparation, pastes for spreading, milk crumb
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G2200/00—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF containing organic compounds, e.g. synthetic flavouring agents
  • A23G2200/12—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF containing organic compounds, e.g. synthetic flavouring agents containing dairy products
• • A—HUMAN NECESSITIES
  • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
  • A23G—COCOA; COCOA PRODUCTS, e.g. CHOCOLATE; SUBSTITUTES FOR COCOA OR COCOA PRODUCTS; CONFECTIONERY; CHEWING GUM; ICE-CREAM; PREPARATION THEREOF
  • A23G2220/00—Products with special structure

Definitions

• TITLE METHOD FOR PRODUCING AN ACIDIC OR NEUTRAL FRESH MILK PRODUCT CONTAINING PIECES OF CHOCOLATE OR A CHOCOLATE-LIKE PRODUCT, FROM A SWEETENED PREPARATION
• the present invention relates to a method for producing a sweetened aqueous preparation containing pieces of chocolate or a chocolate-like product, and for preparing an acidic or neutral fresh milk product containing pieces of chocolate or a chocolate-like product, from this sweetened preparation.
• microbiological contamination certain molds, yeast and vegetative bacteria naturally present in chocolate develop on contact with the water content of the fresh milk product. It is necessary to sterilize or pasteurize the chocolate; however, conventional pasteurization scales are ineffective on chocolate, because of its low Aw.
• the materials and methods used must be ultra- clean in order to prevent bacterial contamination or re- contamination; poor water resistance: a standard chocolate is soft after 5 hours in a yoghurt. However, it is necessary for the chocolate to keep its crunchiness .
• Fresh milk products that contain pieces of unpasteurized chocolate are known in the prior art. However, in this case, preserving agents must be used or the shelf-lives of these milk products are short ( ⁇ 12 days) .
• Zentis patent application EP 976 333 describes chocolate pieces (chips) obtained by crystallization of the chocolate upon contact with a cold gas (and not with an aqueous liquid) . These chocolate pieces can then be used as milk product additives.
• Patent application WO 00/70960 describes a solid chocolate or chocolate-like product, advantageously in the form of grains, that can be brought into contact with a wet mass such as a milk base.
• the chocolate grains are not prepared and added to the milk base via a sweetened aqueous preparation.
• Standard chocolate i.e. chocolate which has not undergone thermal decontamination
• Patent application EP 615 692 describes a method of crystallizing chocolate by injection into a neutral cold dairy mousse, followed by milling of the band of chocolate obtained.
• this method requires the use of a very bitter chocolate (between 1 and 10% by weight of sugar, advantageously between 1 and 3% by weight of sugar) , i.e. not very sweetened, the product obtained therefore not being very satisfactory for the consumer.
• a very bitter chocolate between 1 and 10% by weight of sugar, advantageously between 1 and 3% by weight of sugar
• the chocolate used in this method has a fat content of 24 to 45% by weight, which does not make it possible to maintain the crunchiness throughout the conservation of the product .
• a chocolate with a higher fat content which is much more fluid in the molten state, means that:
• the device described in the General Mills patent would not make it possible to use such fatty chocolates: firstly, there would, with the injection device indicated (perpendicular to the powerful flow of yoghurt in order to break up the chocolate) , be a risk of the chocolate mixing with the yoghurt before it had crystallized (giving a brown yoghurt) ; in addition, the additional need for refrigeration in order to crystallize the chocolate with a higher fat content would not longer allow the solidification and instantaneous fragmentation described.
• Patent WO 00/07456 describes a method for sterilizing chocolate or a chocolate-like product that makes it possible to minimize the organoleptic damage thereto. This chocolate or chocolate-like product can then be used in fresh milk products in the form of chips.
• that patent does not describe the method for preparing a fresh milk product containing chocolate chips or chips of a chocolate-like product, nor the possibility of using a sweetened aqueous preparation containing said chips .
• the chocolate pieces keep their crunchiness throughout the shelf life of the milk product, without requiring the use of preserving agents or dual compartments.
• the advantages of simple pasteurization compared with sterilization are as follows:
• the chocolate and the sweetened aqueous preparation must be sterilized.
• a chocolate or an aqueous preparation that have only been pasteurized cannot be used.
• the method discovered does not necessitate investing in a complete production line for each fresh milk product-metering device in each factory.
• any interruption in the production of the pasteurized or sterilized chocolate/injection does not stop the production of the milk product containing chocolate pieces.
• the method of production by injection of the pasteurized or sterilized chocolate in the liquid state into a sweetened aqueous preparation and crystallization by taking advantage of the coldness of the sweetened aqueous preparation makes it possible, while ensuring the microbiological control of the ingredients, to overcome the following obstacles: preventing the chocolate from mixing with the sweetened aqueous preparation, which would reduce the water resistance (maintaining of the crunchiness of the chocolate) , or would even turn the sweetened aqueous preparation brown; preventing hydration of the chocolate in the sweetened aqueous preparation, which would add to the future hydration in the fresh milk product (the total lifetime in contact with an aqueous product is approximately doubled) .
• the chocolate formulations used are only a water barrier if the fat is sufficiently crystallized.
• SFC solid fat content
• the method must therefore comprise a step consisting in cutting the chocolate, but this step must minimize the loss of texture of the sweetened aqueous preparation, which would result in the need to add texturing agents (new ones or in greater amount) ; preventing the demixing of the chocolate pieces in the sweetened aqueous preparation, by controlling the viscosity or gel strength of the sweetened aqueous preparation.
• the present invention therefore relates to a method for producing a sweetened aqueous preparation in which 8 to 30% by weight, advantageously 10 to 30% by weight, advantageously 10 to 20% by weight, relative to the total weight of the preparation, of chocolate pieces are dispersed, which method comprises the following successive steps :
• a sweetened aqueous preparation in which 8 to 30% by weight, advantageously 10 to 30% by weight, advantageously 10 to 20% by weight, relative to the total weight of the preparation, of chocolate pieces having a fat content of between 43 and 85% by weight are dispersed, said preparation being conserved at a temperature of less than 10 0 C for at least 3 weeks, advantageously at least 6 weeks.
• sweetened aqueous preparation is intended to mean any sweetened aqueous preparation with a 25 to 60% water content (without the chocolate pieces) , which may or may not be flavored, and which is intended to be used in acidic or neutral fresh milk products. According to the present invention, this preparation is not based on milk.
• This preparation may contain monosaccharides and disaccharides, glucose syrups or fructose syrups, starch syrups with a D.E. of 21 to 100, soluble fiber, polyols, strong sweeteners (i.e.
• sweeteners which have a sweetening power several hundred times greater than that of sucrose, such as, for example, aspartame, potassium acesulfame or saccharin) , texturing agents, dyes, flavorings, fiber, cocoa, fruits, etc.
• the Aw measured at 25°C will be ⁇ 0.96, advantageously ⁇ 0.95, and even more advantageously ⁇ 0.93.
• the pH of the preparation is neutral (advantageously between 4.8 and 7.3) or acidic (advantageously between 3.0 and 4.8) .
• the acidification is obtained with one or more food acids, advantageously with lactic acid, citric acid or phosphoric acid.
• the texture of the sweetened aqueous preparation will have to be sufficiently gelled to prevent settling out of the chocolate pieces due to gravity/Archimedes pressure, for at least 3 weeks.
• the sweetened aqueous preparation will necessarily comprise a gel-forming agent, for example of the pectin or gel-forming carragheenans type, advantageously at a dose ⁇ 1.5%, preferably of between 0.15 and 0.7%.
• gel-forming agents will be used in the presence of a dose of calcium suitable to be functionalized, as known to those skilled in the art.
• this gel-forming agent will be combined with one or two thickeners : a modified starch such as acetylated distarch adipate (advantageously ⁇ 5%, advantageously between 1 and 4%) ; - another thickener: either xanthan gum (advantageously ⁇ 0.15%, advantageously between 0.01 and 0.08%), or another thickener chosen from the group consisting of guar flour, carob flour or caragheenans (advantageously between 0.05 and 0.8%, advantageously at 0.2%) .
• a modified starch such as acetylated distarch adipate (advantageously ⁇ 5%, advantageously between 1 and 4%)
• - another thickener either xanthan gum (advantageously ⁇ 0.15%, advantageously between 0.01 and 0.08%), or another thickener chosen from the group consisting of guar flour, carob flour or caragheenans (advantageously between 0.05 and 0.8%, advantageously at 0.2%)
• the dose of thickener and of gel-forming agent used will be adjusted by those skilled in the art, in particular so as to take into account the water content and the thickening effect of the other ingredients (in particular, glucose-fructose syrup or starch syrup or soluble fiber) .
• the rheological behavior of the sweetened aqueous preparation is evaluated using a viscoelastometer (Physica MCR300, Anton Paar) .
• This equipment makes it possible to evaluate the viscoelastic behavior of a material, i.e. to quantify the respective contributions of solid type (in the form of the elastic modulus G') and of liquid type (in the form of the viscous modulus G") , under given temperature, frequency or strain conditions.
• the protocol used is as follows: the sample is placed in a measuring cylinder.
• the moving part for measurement is a layout of 6-vane shear device type, especially designed to measure the rheology of fragile fluids (such as those which are thixotropic : gelled, etc.) and/or fluids containing pieces.
• the measurement is carried out directly on the sweetened aqueous preparation containing the chocolate pieces, stored beforehand for at least 36 hours at 10 0 C.
• the results are generally as follows:
• the frequency scan shows an elastic modulus that dominates the viscous modulus over the entire frequency range examined: this indicates that, at the low strains used, the material behaves essentially as a solid. This behavior is linked to the existence of a three-dimensional gel network created by weak interactions between chains of texturing agents (elastic modulus typically between 10 2
• the strain is gradually increased, which leads to a decrease, which is first gradual and then more marked, in the viscoelastic moduli.
• the elastic modulus becomes less than the viscous modulus, which indicates that the material behaves, overall, as a liquid.
• the gradual increase in strain produced in this test therefore causes weakening and then rupture of the gel network. This is what will allow the material to flow like a viscous liquid, and to be withdrawn by pumping before use in the final milk product.
• “chocolate-like product” is intended to mean any confectionery fatty mass, with a water content ⁇ 4% by weight (before being brought into contact with an aqueous product) , containing a continuous fatty phase consisting of one or more fats of vegetable or animal origin and whose properties are similar to those of cocoa butter (crunchy texture) . These fatty masses are generally called coating chocolate or compound.
• This chocolate or this chocolate-like product can be flavored with caramel, with coffee, with mint, etc., as a supplement or as a substitution for the cocoa.
• the chocolate comprises between 65 and 78% by weight of fat, advantageously between 68 and 78% by weight of fat, advantageously between 74% and 76% by weight of fat, relative to the total weight of the chocolate.
• the fat is cocoa butter. It is, however, possible to replace up to 20% by weight of the cocoa butter with anhydrous milk fat (AMF) or to replace all or some of the cocoa butter with one or more vegetable fats having an SFC at 10 0 C (solid fat content) of greater than 50% by weight.
• the fat can also be solely a fat of vegetable origin, in particular lauric fats: for example, hydrogenated fractionated palm kernel oil (sold by Fuji Oil Europe) .
• cocoa butter contained in cocoa powder (10-12% fat) is, however, tolerated, but care will be taken to maintain the cocoa butter/total fat ratio at preferably ⁇ 5%, so as to maximize the crunchiness.
• Very high fat chocolates are unstable: there is rapid sedimentation due to the low viscosity, hence a heterogeneity in the recipe, and therefore a heterogeneity in the taste and in the water resistance.
• the chocolate purchased will have a low fat content, so as to have a viscosity > 0.5 Pa.s at 4O 0 C (according to the
• the chocolate has a sugar concentration of greater than 5% by weight, advantageously greater than 10% by weight, even more advantageously greater than 11% by weight, relative to the total weight of the chocolate.
• this sugar content is approximately 14% by weight, relative to the total weight of the chocolate.
• the sugars are in particular monosaccharides and disaccharides. Among monosaccharides, mention may be made of fructose, galactose or glucose.
• sucrose which is the sugar commonly used for producing chocolate
• sucrose can be partially or completely replaced with another disaccharide, such as lactose, for example in an amount of 0 to 50% by weight, or with polyols which, at the jacket temperature during the pasteurization or sterilization step, do not melt and do not release crystallization water.
• lactose lactose
• polyols which, at the jacket temperature during the pasteurization or sterilization step, do not melt and do not release crystallization water.
• mannitol and maltitol are, however, sucrose.
• the sweetened aqueous preparation containing chocolate pieces according to the present invention is intended to be incorporated into an acidic or neutral fresh milk product .
• this sweetened aqueous preparation will be mixed with an intermediate fresh milk product, that has a local free water content greater than that of the sweetened aqueous preparation.
• C is the content of dry and defatted cocoa of the chocolate (in g/g) .
• the local free water content [local free water] is defined by the following equation (2) :
• FM is the fat of the final fresh milk product, expressed in grams of fat per 100 grams of the final fresh milk product (excluding chocolate pieces) ;
• total water is given in grams of water per 100 grams of the final fresh milk product (excluding chocolate pieces) .
• the local free water content is 73.9%.
• a sweetened aqueous preparation has a local free water content of between 27 and 60%.
• the value of ⁇ must not exceed a limiting value in order to ensure water resistance and therefore a crunchiness that is sufficient.
• the value of ⁇ will have to be chosen according to the duration of conservation and the temperature of conservation of the sweetened aqueous preparation containing the chocolate pieces. The shorter the duration or the lower the temperature, the higher this value may be.
• ⁇ is advantageously less than 2, preferably less than 1.6.
• composition of the chocolate having the appropriate characteristics in the context of the present invention is therefore defined in particular by means of a test described in the form of a mathematical equation which means that those skilled in the art do not have to carry out experiments.
• an experimental procedure that allows those skilled in the art to determine the chocolate compositions which satisfy the aims that the invention proposes to achieve is indicated below. '
• the test which consists in bringing slices of chocolate 1.5 + 0.2 mm thick and 20 mm in diameter into contact with an agar gel having a determined local free water content of 74% is carried out.
• the chocolate slices are obtained after tempering and cooling of the chocolate to 13°C, and storage for 2 days at 20 0 C and then for 12 hours at 10 0 C.
• the gel is poured into syringes which are cut at their end and then covered with the slice of chocolate and are then closed again with a stopper.
• the whole is stored for 35 days at 1O 0 C and the water uptake of the slice of chocolate is measured at D35 by the "Karl Fischer" method, OICC No. 105 (1988) .
• compositions which satisfy the criteria of the invention are those whose percentage water uptake after 35 days of storage at 1O 0 C will be ⁇ 17.7%; table 1 below gives an indication of the percentages of water uptake after 35 days at 1O 0 C as a function of the water resistance of the chocolate.
• Table 1 Percentages of water uptake in g/100 g after 35 days at 10°C as a function of the water resistance of the chocolate
• a gel composition having a local free water content of approximately 74% is given below in table 2.
• Table 2 % composition, by weight, of gel having a local free water content of approximately 74%
• the chocolate used in the context of the present invention may be dark chocolate, milk chocolate or white chocolate.
• the chocolate used in the context of the present invention corresponds to the formulae indicated in table 3 below:
• the cocoa mass contains, as % by weight: 1.7% water
• the dark chocolate contains, as % by weight: 0.5% water, 27.7% fat (approximately 0.3% of which is lecithin) , 22.3% dry defatted cocoa and 49.5% sugar; advantageously, the particle size thereof measured with a Palmer is ⁇ 30 ⁇ m, and the contamination thereof is advantageously ⁇ 1000 cfu/g; the cocoa powder containing 11% fat contains, as % by weight: 4% water, 11% fat and 85% dry defatted cocoa.
• composition of the recipes of the lauric chocolate- like products is given in table 5 below.
• particle size thereof measured with a Palmer is
• the hydrogenated and fractionated vegetable fat used in tables 4 and 5 is hydrogenated palm kernel stearin (i.e. hydrogenated and fractionated) .
• palm kernel stearin i.e. hydrogenated and fractionated
• Two advantageous examples are available from Fuji Oil Europe (ref: Palkena H50 -G or HB7 G) .
• the solid fat content of these two plant fats is given in table 6 below.
• HPKS Palkena HPKS Palkena
• the method according to the present invention comprises a step ( ⁇ ) , prior to step (a) , consisting of preparation of the chocolate, advantageously by mixing the fat and the chocolate, and optionally the cocoa mass and/or the cocoa powder.
• the ingredients used are cocoa mass, dark chocolate, cocoa powder containing 11% by weight of fat and cocoa butter in the case of chocolate, and the lauric dark chocolate-like product, hydrogenated and fractionated vegetable fat and cocoa powder 10-12 in the case of the chocolate-like product.
• the proportions used are those indicated in tables 3 to 5 for formulae 1 to 4 and recepies 1 and 2.
• the chocolate, prepared on site in step ( ⁇ ) or purchased, is deaerated under vacuum before it is used in the method according to the present invention (i.e. before step (a) of the method) .
• Such a deaeration can make it possible to obtain a better effectiveness of the thermal treatment and a better water resistance (more compact chocolate) .
• Step (a) of the method according to the present invention therefore consists of pasteurization or sterilization of the chocolate.
• step (B) of the method according to the present invention consists of the injection of the sweetened aqueous preparation containing the chocolate pieces into an acidic milk base.
• thermo-resistance of A. niger spores in artificial contamination in chocolate ⁇ 1% of water
• D 70 o C 2000 min
• 2000 min at 70 0 C reference temperature
• Fz is calculated by time x temperature integration, as is conventionally done in the food preservation industry (appertization) .
• EP Fz/D 70° c / which measures the logarithmic decrease in the population for the given thermal treatment.
• a little water, preferably in the form of steam, can be injected in order to pasteurize the chocolate during step
• (a) It may be, for example, a proportion of 0.5 to 1% by weight relative to the total weight of the chocolate. This can make it possible to improve the pasteurization if the starting materials are very contaminated: it is not then necessary to evaporate the water introduced, given the small amounts used.
• the pasteurization step (a) is carried out dry.
• this step (a) is carried out by heating, optionally under pressure.
• this step (a) comprises the following successive steps:
• the gases and the steam can exit via a sterile filter (or sintered glass) ;
• the steam can be degassed just after the end of pasteurization (before cooling) by being placed in the open air and/or by being placed under vacuum.
• Option 2 gives a slightly greater effectiveness of pasteurization of the chocolate, but may cause some sugar aggregates in the pasteurized chocolate.
• the chocolate is pasteurized during step (a) by means of a batch method, advantageously in a device equipped with a pasteurization tank that has a double-walled jacket, advantageously equipped with a stirrer that scrapes the walls.
• the heating fluid in the double-walled jacket is hot water (optionally overheated for temperatures > 100 0 C) , steam (in particular for pasteurization temperatures > 100 0 C) or any other heat- transfer fluid (oil, for example) .
• the steam pressure in the double-walled jackets will be ⁇ 150 KPa in absolute pressure, so as to limit the wall temperature to a temperature ⁇ 111°C.
• step (a) of the method can be carried out : batchwise; the pasteurization tank can thus serve as a buffer tank before the metering device/use (for a continuous production, 2 tanks are required, in parallel) .
• the tank and the piping of the device implementing the method according to the present invention are pasteurized at the same time as the chocolate;
• the device used for the pasteurization comprising no pasteurization tank, but a heat exchanger, for example with a scraped surface (with an installation devoted to pasteurization, there is never any need for cleaning: it is sufficient to pasteurize the downstream piping with chocolate according to the scale above, and to send the chocolate insufficiently pasteurized into the starting tank so as to recycle it) .
• the same tank is used for implementing steps (a) and ( ⁇ ) .
• the method according to the present invention comprises an intermediate step (al) , between steps (a) and (b) , consisting of storage with stirring of the pasteurized chocolate at a temperature of between 28 and 75°C, advantageously between 65 and 75 0 C, optionally without overpressure.
• the chocolate can be stored under pressure (step (al) ) , advantageously at a temperature of between 28 and 50 0 C, advantageously between 10 and 30 KPa.
• a temperature of between 28 and 50 0 C advantageously between 10 and 30 KPa.
• the storage temperature is ⁇ 36°C, the lower the temperature, the shorter the storage time will have to be (risk of solidification) .
• storage at 33 0 C can be carried out for approximately 40 hours without too marked an increase in viscosity (its viscosity at 33°C is of the order of 0.26 Pa. s under a strain of 150 Pa) .
• the storage is carried out under pressure at a temperature of between 28 and 38 0 C, preferably between 30 and 34 0 C.
• the storage is carried out under pressure at a temperature of between 38 and 50 0 C, advantageously at a temperature of 45 0 C.
• the storage is carried out at a temperature of between 65 and 75 0 C without overpressure, i.e. at atmospheric pressure.
• the chocolates which are very fluid, must be permanently stirred, in order to prevent settling out of the solid particles in suspension and fat separation.
• step (al) is carried out in a device equipped with an intermediate buffer tank.
• the chocolate is stored in the pasteurization tank of step (a) .
• the same tank is used for steps (a) and (al) .
• the same tank is used for steps ( ⁇ ) , (a) and (al) .
• step (c) it is advisable to maintain the pasteurization of the chocolate before it is injected during step (c) . If the pasteurized chocolate remains stored in the pasteurization tank during step (al) , this avoids having to pasteurize a downstream tank, and the tank is thus pasteurized at each batch at the same time as the chocolate. Since the chocolate is anhydrous, it is not necessary to clean between two batches, unless the flavors or colors of the chocolate are incompatible. No time is therefore lost due to cleaning/pasteurization of the tank. In order to prevent any recontamination, the tank is advantageously pressurized by a sterile gas source (typically, 10 to 30 KPa) .
• a sterile gas source typically, 10 to 30 KPa
• all the pipework downstream of the injection step (c) in the device for implementing the method according to the present invention, is advantageously pasteurized dry, in particular at the same time as the pasteurization of the chocolate at each batch, advantageously with a device having a double-walled jacket at 100°C/10 to 20 min, after cleaning or without cleaning.
• Other dry sterilization techniques exist, for example with hot fat (100°C/l0 min) .
• the pipework downstream of the injection step (c) in the device for implementing the method according to the present invention, can also be pasteurized conventionally by cleaning in place, and then pasteurization with hot water or steam: however, it is necessary to drain off the water and preferably dry the installation before sending the pasteurized chocolate thereto (sterile gas stream, or vacuum, heated by double- walled jackets, for example filled with steam at 110 KPa in absolute pressure) .
• step (al) is carried out in a device equipped with an intermediate buffer tank, i.e. steps (al) and (a) are not carried out in the same tank, the following two cases exist : - the storage (step (al) ) is carried out at a temperature of less than 60-65 0 C.
• the intermediate buffer tank will then have to be pasteurized during the 1st use and each time the pasteurized state is lost (since the chocolate is virtually anhydrous, no microbial development can take place, except in an exceptional case: maintenance, etc.) . This may be carried out conventionally
• step (cleaning, then hot water sanitization, then evaporation) or preferably by heating ensuring a pasteurization strength Fz > 6000 min (for example, 22 h at 75 0 C) , preferably Fz > 20 000 min; the storage (step (al) ) is carried out at a temperature > 75 0 C so as to have "continuous" pasteurization.
• steps (a) and (al) should avoid the incorporation of air, which reduces the water resistance of the chocolate.
• degassing for example, by placing the pasteurization and/or batch storage tank under vacuum
• the chocolate is sterilized.
• the method described in patent application WO 00/07456 is used.
• the water activity (Aw) of the chocolate is increased to a value greater than approximately 0.7, advantageously greater than 0.8
• the hydrated chocolate is subjected to a heat sterilization step, and the water is eliminated so as to recover an essentially sterile chocolate, which exhibits a contamination, in particular with respect to sporulated bacteria, that is at least 1000-fold less (3 log) than the starting chocolate, in particular less than 1 CFU/g.
• the water activity is increased to a value of greater than 0.87, in particular between 0.9 and 0.96.
• this method is carried out batchwise in the same tank.
• the invention makes it possible in particular to obtain a reduction in microorganisms, of between 3 and 12 log (1000 to 10 12 times less) , in particular between 3 and 9 log, and advantageously of at least 5 log with respect to sporulated bacteria, advantageously of at least 6 log.
• a reduction in microorganisms of between 3 and 12 log (1000 to 10 12 times less) , in particular between 3 and 9 log, and advantageously of at least 5 log with respect to sporulated bacteria, advantageously of at least 6 log.
• this makes it possible to obtain an "essentially sterile" chocolate containing less than 1 CFU/g, preferably less than 1 CFU/lOO g, and preferably less than 1 CFU/kg.
• the water activity of a product is a notion that is well known in the food sector, this parameter, abbreviated to Aw, measures the water availability in a sample. In most cases, this water activity is not proportional to the water content of the product.
• the Aw is generally measured at 25°C.
• This sterilization method is particularly suitable for the treatment of dark chocolate. However, this method is also suitable for the production of various types of milk chocolate or white chocolate, that are essentially sterile. It is, for example, known that white chocolate contains no dry and defatted cocoa.
• the required water is added either entirely at the start, or partly at the start and partly during the heating to the sterilization temperature for the chocolate, or only during the heating. This addition of water during the heating will advantageously be carried out by direct injection of food-quality steam into the chocolate.
• the water can be added in pure form, or via aqueous compounds, for instance milk (skimmed or non-skimmed, concentrated or non-concentrated) , cream or other milk derivatives, fruit juices, etc.
• aqueous compounds for instance milk (skimmed or non-skimmed, concentrated or non-concentrated) , cream or other milk derivatives, fruit juices, etc.
• Aw is measured in the following way and is referred to as equivalent Aw:
• the proportion of water corresponding to the total water content that will be added at the end of the sterilization step is added to the chocolate, in a suitable laboratory mixer. Stirring is carried out for 15 min at 50 0 C, avoiding any evaporation, and the mixture is left to stand at 20 0 C in a closed flask containing little head space. After 24 hours, the chocolate is reduced to fine powder or is mixed (according to its consistency) and its Aw is measured at 25°C on a conventional device of Aqualab CX-2 or Decagon type.
• step (b) of the method consists in cooling the pasteurized or sterilized chocolate to a temperature of between 24 and 45 0 C, advantageously between 24 and 38 0 C.
• step (b) consists in tempering and cooling the chocolate to a temperature of between 24 and 30 0 C.
• the chocolate is not tempered, it is cooled to a temperature of between 30 and 45 0 C, advantageously between 30 and 4O 0 C.
• the tempering of the chocolate is not obligatory in fresh products, i.e. in the method according to the present invention, as it is for conventional applications stored at ambient temperature. However, it accelerates the solidification of the chocolate and slightly improves its crunchiness .
• the tempering may be carried out by means well known to those skilled in the art in the chocolate making industry. It may thus be very simplified, since, although in the chocolate making industry only V-shaped (stable) chocolate crystals are selected, chocolate crystals of any shape can be accepted here, since the storage conditions according to the present invention will prevent any whitening.
• the essential aim of the tempering is therefore simply to accelerate the solidification of the chocolate on contact with the sweetened aqueous preparation during step (d) of the method according to the present invention, in particular by starting from a lower chocolate temperature and by having already crystallized part of the fat of the chocolate.
• step (b) is carried out either directly in the storage tank of the optional step (al) , or on line, advantageously using a device equipped with a heat exchanger (for example, a scraped-surface exchanger) .
• a heat exchanger for example, a scraped-surface exchanger
• the on-line scraped-surface exchanger allows the chocolate to be cooled to a lower temperature, since the chocolate does not remain at this temperature for very long and will not have the time to solidify.
• step (c) of the method according to the present invention consists of the injection of the pasteurized or sterilized, cooled chocolate into a stream of pasteurized or sterilized, sweetened aqueous preparation having a temperature between the freezing point of the sweetened aqueous preparation and 15°C, advantageously between the freezing point of the sweetened aqueous preparation and 10 0 C.
• the sweetened aqueous preparation according to the invention is pasteurized or sterilized by methods well known to those skilled in the art. Given the fact that chocolate melts above 40 0 C, it is necessary to pasteurize or sterilize the sweetened aqueous preparation separately, without the chocolate pieces, and then to introduce and solidify the chocolate in this preparation. The preparation should subsequently never be taken to more than 25 0 C, advantageously not to more than 20 0 C, so as not to melt the chocolate, or simply degrade its water resistance.
• step (c) is carried out by continuous injection of the chocolate in the form of strips into the sweetened aqueous preparation.
• step (e) consists of the injected and solidified, pasteurized or sterilized chocolate being cut into pieces and mixed into the pasteurized or sterilized, sweetened aqueous preparation, by means of a dynamic mill, and the longest dimension of the chocolate pieces obtained in step (e) is advantageously between 1 and 6 mm, advantageously between 4 and 6 mm.
• the solidification time in step (d) is between 30 and 600 s.
• the injection of the chocolate into the sweetened aqueous preparation according to variant 1 of step (c) of the method according to the present invention is therefore carried out in a continuous stream.
• the chocolate is therefore advantageously injected in the form of "strips" of varied cross section (round, rectangular, cross-shaped, etc . ) .
• the injecting device used deposits the stream of chocolate in the middle of the stream of sweetened aqueous preparation.
• the stream of sweetened aqueous preparation is parallel to the stream of injected chocolate.
• the linear speed of the stream of chocolate on leaving the injecting device is equal, to within ⁇ 40%, to that of the stream of sweetened aqueous preparation.
• step (c) is carried out by injection of the chocolate into the middle of the stream of the sweetened aqueous preparation, the stream of chocolate being parallel to the stream of sweetened aqueous preparation and the linear speed of the stream of chocolate on leaving the injecting device being equal, to within + 40%, to that of the stream of sweetened aqueous preparation.
• the injection flow rate should be calculated according to the desired proportion of chocolate in the sweetened aqueous preparation.
• the linear speed of the chocolate should advantageously be as close as possible to that of the sweetened aqueous preparation (carrier fluid) .
• the flow between the stream of sweetened aqueous preparation and the stream of chocolate should be laminar (same speed) before and after the injection step (c) so as to prevent mixing between the non-solidified chocolate and the sweetened aqueous preparation.
• the injection in step (c) is carried out using a device equipped with an injection nozzle.
• the injection nozzle diameter will be such that the speed of the chocolate in the nozzle and the speed downstream are similar (to ⁇ 40%) .
• the injection is carried out using a multi-injector: this makes it possible to reduce the diameter (in the case of a round injecting device that makes it possible to obtain strips with a round cross section) of the chocolate strips compared to when a single injecting device is used, for the same proportion of chocolate, and therefore to accelerate the ratio of crystallization.
• the diameter of the strips with a round cross section will be between 2 and 8 mm, advantageously between 4 and 6 mm.
• the injecting device used has a rectangular cross section and makes it possible to obtain a chocolate strip with a rectangular cross section, advantageously having a thickness of between 2 and 8 mm, even more advantageously of between 4 and 6 mm.
• the injection nozzle which is cooled by the stream of cold sweetened aqueous preparation, it will be insulated or insulating (for example made of Teflon ) or heated
• the injecting device in step (c) is placed at the center of the tube.
• the method according to the invention is carried out in a device that has a nonreturn valve in order to separate the stream of chocolate obtained in step (b) from the stream of sweetened aqueous preparation.
• step (d) of the method according to the present invention consists of the solidification of the continuously injected, pasteurized or sterilized chocolate.
• This solidification is due to the contact of the chocolate with the sweetened aqueous preparation (having a temperature between the freezing point of the sweetened aqueous preparation and 15°C, advantageously between the freezing point of the sweetened aqueous preparation and 10 0 C) .
• the device for implementing step (d) consists of a portion of linear pipework of equal diameter, with no pipe failures.
• this device is equipped with a double- walled jacket so as to improve heat transfer (the water circulating in the double-walled jacket at a temperature between the "freezing temperature + 1°C" and the temperature of the sweetened aqueous preparation) .
• this device makes it possible to cool the "sweetened aqueous preparation + chocolate strip" combination.
• step (e) of the method according to the present invention In order for the chocolate to solidify, it must be cooled to less than 14°C, preferably to less than 10 0 C, preferably to less than 6°C, before step (e) of the method according to the present invention. If the chocolate is insufficiently solidified at the time of step (e) of the method according to the present invention, it will still be elastic at the center and the chocolate will, in general, be less water resistant.
• the solidification time in step (d) is between 30 and 600 s.
• the device for implementing step (d) of the method according to the present invention is equipped with a length of pipework that is sufficient to ensure the solidification time of the chocolate.
• this length is between 3 and 40 m.
• This pipework can be placed vertically in order to limit the impact of movement linked to Archimedes pressure in the event of the machine stopping.
• the method according to the present invention advantageously comprises an intermediate step (dl) , between steps (d) and
• step (e) of the method according to the present invention consists of the pasteurized or sterilized, solidified chocolate being cut into pieces and mixing it into the pasteurized or sterilized, sweetened aqueous preparation by means of a dynamic mill.
• the dynamic mill is chosen from the group consisting of rotary blades, propellers, centrifugal
• the stator has large openings so as to prevent blockages .
• the dynamic mill provides a low rotation speed (m/s) (for example: worm + counter blade) which causes less prestructuring of the sweetened aqueous preparation.
• m/s for example: worm + counter blade
• the dynamic mill is equipped with a counter blade.
• the counter blade serves as a support and makes it possible to cut the chocolate with a lower rotation speed.
• the regulatable rotation speed makes it possible to adjust the size of the chocolate pieces.
• the dynamic mill is a rotor/stator with screen or a simple rotor (cross, centrifugal pump type) without screen + counter blade (the chocolate ribbon is held by the counter blade at the cutting point) . This allows better control of the maximum size of the chocolate pieces, thus making it possible to prevent blocking of the metering device downstream.
• step (c) variant 1
• a large amount of chocolate is injected in proportion to the sweetened aqueous preparation (advantageously between 50% and 95% by weight of chocolate advantageously between 65 and 90% by weight of chocolate, advantageously between 75 and 85% by weight of chocolate, the remainder consisting of the sweetened aqueous preparation) and the rest of the sweetened aqueous preparation is added in step (e) so as to obtain, during step (f) , a sweetened aqueous preparation containing the desired amount of chocolate pieces.
• the longest dimension of the chocolate pieces obtained in step (e) is between 1 and 6 mm, advantageously between 4 and 6 mm.
• step (c) is carried out by dropwise injection of the chocolate above the pasteurized or sterilized, sweetened aqueous preparation.
• step (e) consists in mixing, by stirring in general without cutting, the solidified drops of pasteurized or sterilized chocolate into the pasteurized or sterilized, sweetened aqueous preparation.
• cutting can also follow this step, in particular so as to increase productivity while at the same time eliminating "doubles" (pieces stuck together) .
• the stirring in step (e) is carried out with a dynamic mixer, advantageously chosen from the group consisting of a stirred tank or a conveying device, such as a worm or an inclined plane or any other device well known to those skilled in the art. This stirring makes it possible first to prevent 2 successive injections of liquid chocolate from sticking to one another before solidification (preventing doubles or agglomerates) , and then enables homogeneous distribution of the solidified drops of chocolate.
• step (d) of the method consists of the solidification of the injected drops of pasteurized or sterilized chocolate.
• This solidification is due to the contact of the chocolate with the sweetened aqueous preparation (having a temperature between the freezing point of the sweetened aqueous preparation and 15°C, advantageously between the freezing point of the sweetened aqueous preparation and 1O 0 C) .
• the device for implementing step (d) consists of a stirred tank.
• this device is equipped with a double-walled jacket so as to improve heat transfer (the water circulating in the double-walled jacket at a temperature between "the freezing temperature + I 0 C" and the temperature of the sweetened aqueous preparation) .
• step (f) of the method according to the present invention consists of the recovery of a sweetened aqueous preparation in which 8 to 30% by weight, advantageously 10 to 30% by weight, advantageously 10 to 20% by weight, relative to the total weight of the preparation, of pieces of pasteurized or sterilized chocolate having a fat concentration of between 43 and 85% by weight, are dispersed, said preparation being conserved at a temperature of less than 10 0 C for at least 3 weeks, advantageously at least 6 weeks.
• the amount of 8 to 30% by weight of chocolate in the sweetened aqueous preparation (preferably 10 to 20% by weight) is obtained in one or more passages by recirculation so as to perform a gradual enrichment
• steps (c) to (e) are repeated at least once before step (f) , the stream of sweetened aqueous preparation containing less than 8 to 30% by weight, advantageously less than 10 to 20% by weight of chocolate obtained in step (e) being re-used in steps (c) to (e) , as pasteurized or sterilized, cooled sweetened aqueous preparation.
• the method according to the present invention comprises an additional step (g) consisting of storage of the sweetened aqueous preparation in which 8 to 30% by weight, advantageously 10 to 20% by weight, relative to the total weight of preparation, of chocolate pieces are dispersed, obtained in step (f) , at a temperature of between 1 and 10 0 C, advantageously between 1 and 4 0 C.
• the storage is carried out in a tank or container, which may or may not be mobile.
• the storage is carried out with or without stirring.
• the storage time can range up to 3 weeks, advantageously up to 6 weeks.
• the present invention also relates to a method for producing an acidic or neutral fresh milk product containing chocolate pieces, which method comprises the following steps:
• the term "acidic or neutral milk base” or “acidic or neutral milk product” is intended to mean any milk product that is fermented or acidified via ingredients (advantageously, with lactic acid, citric acid or phosphoric acid) (its pH is advantageously less than 4.8, it is advantageously between 3 and 4.8) or that is neutral (its pH is advantageously between 4.8 and 7.3, advantageously between 5.5 and 6.8) .
• it may be a fromage frais or a fermented product containing live ferments (for example, sour cream, kefir, or the like) and in particular a yoghurt or similar fermented milk specialty products (fermented with lactic acid bacteria, such as active bifidus or L.
• the product is fermented by the addition of live ferments such as, for example, Lactobacillus bulgaricus, Streptococcus thermophilus and/or Lactobacillus acidophilus and/or bifidus.
• the milk used in the milk base is cow's milk.
• other milks can be used as complete or partial substitution for the cow's milk, such as, for example, goat's milk, yew's milk, buffalo milk or mare's milk, or less advantageously milks of vegetable origin, such as soya milk, coconut milk or oat milk.
• the pasteurized and optionally fermented, acidic or neutral milk base is obtained according to methods well known to those skilled in the art.
• the method for obtaining a fermented pasteurized acidic milk base comprises the following successive steps:
• raw milk which may also contain a combination of whole milk, skimmed milk, condensed milk, dry milk (defatted dry extract of milk or equivalent) , category A lactoserum, cream and/or other milk fraction ingredients, such as, for example, buttermilk, lactoserum, lactose, lactalbumin, lactoglobulin or lactoserum modified by complete or partial removal of lactose and/or minerals or other milk ingredients so as to increase the defatted solid content, which are mixed so as to provide the desired fat and solid contents.
• the milk base may contain a filling milk constituent, i.e. a milk ingredient of which a portion consists of a non-milk ingredient, for instance an oil or soya milk.
• the mixing in step (B) is carried out using a static mixer, advantageously with an opening/structure for passing through that is suitable for the chocolate pieces, or a dynamic mixer.
• a static mixer advantageously with an opening/structure for passing through that is suitable for the chocolate pieces
• a dynamic mixer advantageousously, it is a dynamic mixer.
• the product obtained in step (C) comprises no additive or preserving agent.
• it contains no alcohol.
• the milk product obtained in step (C) contains between 0.5 and 6% by weight of chocolate pieces relative to the total weight of the milk product, advantageously between 1 and 4% by weight. It may advantageously have the composition indicated in table 7 below: Table 7 : % composi tion, by weight, of the product obtained in step (C)
• the method according to the present invention comprises an additional step (D) consisting of the metering of the product obtained in step (C) into a thermoformed or preformed decontaminated pot.
• the pot is therefore thermoformed just before filling, or is a preformed decontaminated pot.
• step (D) takes place in an environment in which the microorganisms are filtered out, advantageously under a laminar flow hood that delivers sterile air under slightly reduced pressure, as conventionally in the fresh milk products industry.
• the method according to the present invention comprises an intermediate step (Cl) consisting of buffer storage of the product obtained in step (C) , advantageously in a small buffer tank.
• the method according to the present invention comprises an additional step (E) consisting of optional cooling to a temperature of between 1 and 10 0 C, and of storage at a temperature of between 1 and 10 0 C, of the fresh milk product.
• Figure 1 represents a first example of a device for implementing pasteurization step (a) and step (b) and optional steps ( ⁇ ) and (al) of the method according to the present invention, step (a) consisting of a batchwise dry pasteurization.
• Figure 2 represents a second example of a device for implementing pasteurization step (a) and step (b) and optionally steps ( ⁇ ) and (al) of the method according to the present invention, step (a) consisting of a batchwise dry pasteurization.
• Figure 3 represents a device for implementing pasteurization step (a) and step (b) and optional steps (al) and ( ⁇ ) of the method according to the present invention, step (a) being a continuous dry pasteurization.
• Figure 4 represents a device for implementing steps (c) , (d) and (e) of the method according to the present invention.
• Figure 5 represents a first example of the device for implementing step (e) of the method according to the present invention.
• Figure 6 represents a second example of a device for implementing step (e) of the method according to the present invention.
• Figure 7 represents a third example of a device for implementing step (e) of the method according to the present invention.
• Figure 8 represents a rod box, i.e. a specific dynamic mill that can be used in the context of the present invention and that appears to be the most suitable for cutting chocolate strips in a rectangular cross section with a width > 7 mm (it is then necessary to cut widthwise and lengthwise) .
• the aim of the device represented in figure 1 is to pasteurize and cool (steps (a) and (b) ) and optionally to prepare and store (steps ( ⁇ ) and (al) ) the chocolate according to the method of the present invention.
• This device comprises an inlet (7) , for the ingredients intended for the preparation of the chocolate, a tank (8) for preparing and storing the unpasteurized chocolate, an outlet (9) for the prepared chocolate, a tank (10) for pasteurization and storage of the chocolate under pressure, mounted on scales (11) , an inlet (12) for sterile nitrogen, a vent (13) allowing the gases to leave, equipped with a valve (14) , an outlet (15) for the pasteurized chocolate, equipped with a valve (16) , a pipe
• the chocolate can be prepared in the tank (8) by addition of the ingredients in bulk via the inlet (7) .
• This tank (8) is a stirred tank with a double-walled jacket, mounted on scales (11) , which can also enable storage before pasteurization, for example at 50 0 C.
• the transfer via the outlet (9) into the pasteurization tank (10) can take place by gravity, overpressure, or using a pump.
• the tank (8) does not exist and its preparation takes place directly in the pasteurization tank (10) , the ingredients entering via the pipework (9) .
• The, pasteurized chocolate remains stored in the pasteurization tank (10) : this avoids a tank having to be pasteurized downstream, and the tank (10) is thus pasteurized at each batch at the same time as the chocolate. Since the chocolate is anhydrous, it is not necessary to clean between two batches, unless the flavors or colors are incompatible. There is thus no loss of time due to cleaning/pasteurization of the tank (10) .
• the tank (10) is pressurized by means of a sterile gas source (typically 10 to 30 KPa relative) .
• the preferred variant consists in pasteurizing all the pipework (A, C, (9) , (12) , (13) , (15) ) dry, in particular at the same time as the pasteurization of the chocolate at each batch, since the circulation, during the pasteurization, in tubes A and C (double-walled jackets with preferably the same heating fluid as the pasteurization tank (10) ) .
• these pipes will be either small in diameter relative to the flow rate (as high a rate as possible) , or equipped with static mixers, or with sterile compressed air pumps (for example, 20 s every 10 min in the event of no movement) .
• the heat exchanger (20) is optional: it may make it possible to accelerate heat exchanges, in particular when the surface/volume ratio of the tank (10) is unfavorable (large capacity) . Preferably, it will be of scraped surface type, so as to also be used in cooling (tempering) in step (b) of the method according to the present invention. An overpressure in the circuit will prevent recontamination via the revolving mechanical fittings.
• this part B will be as short as possible, if possible reduced to less than 20 cm in length corresponding to the valve (21) , the nonreturn valve (22) , the pipework B and the outlet to the injecting device/metering device (23) , which will preferably also be pasteurized dry (double- walled jacket at 100°C/l0 to 20 min, after cleaning or without cleaning.
• the nonreturn valve (22) prevents the chocolate (anhydrous) from being contaminated with the water from the sweetened aqueous preparation in the event of reverse pressure.
• the pipework B downstream of the point X can also be pasteurized conventionally by cleaning in place, and then pasteurization with hot water or steam: however, it is necessary to eliminate the water and preferably to dry the installation before sending the chocolate thereto (stream of sterile gas, or vacuum, heated with double-walled jacket, for example filled with steam at 100 KPa in absolute pressure.
• valve (16) can remain closed during the pasteurization and the return C is then nonexistent: it is then necessary to clean/sterilize/dry the entire installation downstream of the point S, conventionally as indicated above.
• the double-walled jacket of the pipework C will advantageously be at a minimum temperature of 4O 0 C, so as to prevent crystallization in the pipe, especially when the metering is carried out at a temperature ⁇ 35°C.
• the valve (21) (3-way) closes the pipework C when the chocolate is injected into the sweetened aqueous preparation: this makes it possible to determine the flow rate injected via the flow meter (19) .
• the pump (17) is controlled by the flow rate indicated by the flow meter (19) .
• the tank (10) is on scales (11) so as to facilitate the management of the ingredients, in particular the use of pasteurized chocolate.
• level detectors capacities, vibrating bimetal, etc.
• the flow rate of chocolate should be even when injected.
• the device in figure 2 comprises a pasteurization and storage tank (10) which is not pressurized, mounted on scales (11) , an inlet (9) for the ingredients for producing the chocolate, a permanent vent (12) equipped with a sterile filter (24) , an outlet (15) for the pasteurized chocolate, equipped with a valve (16) , a pipe
• the tank (10) is not pressurized (and therefore less expensive) , and has been constructed with respect to less strict standards in terms of hygiene than the tank in figure 1. It is connected to ambient air via a sterile filter (24) that acts as a vent (12) to eliminate the steam. After pasteurization, the chocolate is stored at
• the pipework A between the point S and the heat exchanger (20) and C will also be maintained at 70°C-75°C for microbiological reasons (no recontamination in the event of a leak in the pump (17) ) .
• the scales (11) are optional and can be replaced with off ⁇ line weighing out, or else flow meters.
• the 500 ⁇ m filters (18) and the flow meter (19) are optional.
• Figure 3 represents a device comprising a tank (8) for preparation and storage of the unpasteurized chocolate, mounted on scales (11) , an inlet (7) for the ingredients for preparing the chocolate, an outlet (9) for the unpasteurized prepared chocolate, equipped with a valve
• a pipe A equipped with a pump (17) , with a mass flow meter (19) , with 500 ⁇ m filters (18) , with a heat exchanger for the heating and the pasteurization (25) , and with a heat exchanger for the cooling (20) , a pipe C equipped with a nonreturn valve (26) , a 3-way valve (21) and a pipe B equipped with a nonreturn valve (22) and with an outlet to the injecting device or the metering device
• the part between the pasteurizing device (heat exchanger (25) ) and the nonreturn valve (26) of the pipe C is pasteurized by heating the entire conduit at 100°C/20 min. Only then is the cooling device (heat exchanger (20) ) turned on and the valve (16) opened in order to use the chocolate. If the injection is stopped for a few minutes, the chocolate is recycled via the pipework C, the double-wall jacket of which is at 50 0 C. Alternatively, a buffer tank at 7O 0 C + delivery pump can be added before the heat exchanger intended for the cooling (20) . The part of the pipework C downstream of the nonreturn valve (26) is considered to be unpasteurized.
• the pipework C which is not always fed, will be sloping so as to self-empty, or will be equipped with static mixers.
• Figure 4 describes a device for injecting the chocolate into the sweetened aqueous preparation. It comprises the inlets (27 and 28) for the sweetened aqueous preparation, the inlet (29) of the chocolate, a nonreturn valve (22) , a device (30) for injecting the chocolate, a device (31) for solidifying the chocolate, a dynamic mill (32) and an outlet (33) for the sweetened aqueous preparation containing chocolate pieces.
• the nonreturn valve (22) prevents entry of the water into the pasteurized chocolate under any circumstances. It is located just before the injecting device (30) .
• the inlet for the sweetened aqueous preparation is in two parts (27 and 28) which are then combined into a single line so as to inject the chocolate at the center of this coming together.
• the device (31) for solidifying the chocolate consists of a tube that has a double-walled jacket containing water at a temperature of between 1 and 4 0 C.
• the dynamic mill (32) used in this device is a worm.
• the arrows used in the scheme indicate the direction of circulation of the streams of sweetened aqueous preparation and of the product containing the chocolate pieces.
• Figure 5 represents an enlargement of the dynamic mill device (32) in figure 4, which, in this case, consists of a worm. Moreover, this device also comprises a deflector/support blade (34) just before the inlet for the stream consisting of the sweetened aqueous preparation (36) and the solidified chocolate strip (35) into the dynamic mill (32) .
• the arrows used in this scheme indicate the direction of circulation of the streams of sweetened aqueous preparation (36) + solidified chocolate strip (35) and of the product containing the chocolate pieces.
• Figure 6 represents a device similar to that of figure 5, except that the dynamic mill (32) consists of rotary blades.
• Figure 7 represents a device similar to that of figures 5 and 6, except that the dynamic mill (32) consists of a propeller and that the deflector/support blade (34) has holes in it so as to allow the sweetened aqueous preparation (36) to pass through.
• Blocks of 25 kg of solid cocoa butter (20 0 C) are melted in the closed tank (10) , the double-walled jacket being supplied with steam at 100-110 0 C so as to accelerate the melting.
• the other solid ingredients (chocolate, cocoa paste) , purchased as "easy melt” (chips, or pieces typically of 1 to 30 g) , are melted into the cocoa butter at approximately 100 0 C and the double-walled jacket is regulated at 75 0 C.
• the stirring maximum
• the tank (10) is closed, the pump (17) starts up so as to provide circulation in the pipeworks A and C, and the chocolate, subjected to maximum stirring, is brought to
• the tank 10 is permanently opened to the air by means of a vent (12) via sterile filter (24) .
• the chocolate, the tank (10) and the pipe up to the point X are then pasteurized.
• the chocolate is then cooled and maintained at 7O 0 C by regulating the water in the double-walled jacket.
• the taste of the chocolate has not been substantially modified by the pasteurization.
• the residual contamination thereof is less than 1 cfu per 100 g.
• the method for counting yeast + molds ("25°C/5+5" method) is as follows:
• the yeast and mold contamination is counted by diluting the chocolate to 1/lOth in a conventional "malt extract” medium (mixture at 4O 0 C so that the chocolate is clearly fluid) , and then enriching (the molds/yeast initially present) at 25°C/5 days with agitation (molds are aerobic) . At the end of this, 1 ml is taken and deposited on a "malt extract agar” medium and incubated at
• the chocolate is cooled to 26°C by means of a scraped surface heat exchanger located just before the injecting device, and is then injected (round nozzle with a diameter of 5.6 mm, according to the device in figure 4) into a sweetened aqueous preparation.
• Chocolate and preparation have the same speed in the crystallization tube.
• This sweetened and flavored aqueous preparation contains (without the chocolate) 20% by weight of sucrose and 30% by weight (dry equivalent) of invert sugars, flavorings, a gel-forming agent (0.7% by weight of LM pectin) and two thickeners (3% by weight of a modified starch such as acetylated distarch adipate ( ⁇ 5% by weight, preferably 1 to 4% by weight) and 0.2% by weight of carob flour) .
• the water content is 46%.
• the pH is adjusted by adding citric acid such that the former is 4.5 after the 3 weeks of storage of the sweetened aqueous preparation + chocolate pieces.
• a calcium salt is introduced in order to functionalize the pectin to a maximum.
• the freezing point is -4.2 0 C.
• This sweetened aqueous preparation is cooled to -2 0 C by means of a tubular exchanger.
• the nozzle injecting the chocolate is insulated with respect to the sweetened aqueous preparation by means of a double-walled jacket supplied with water at 28 0 C.
• the crystallization time is approximately 80 s.
• the sweetened aqueous preparation containing chocolate pieces is stored for 3 weeks at 10 0 C, and is then used for metering: 80% by weight of a sweetened yoghurt (containing 8% by weight of sugar) at 14 0 C + 20% by weight of the sweetened aqueous preparation with chocolate pieces, using a Dosys " as dynamic mixer.
• the yoghurt used has the composition indicated in table 8 below: Table 8: % composition, by weight, of the yoghurt
• the flavored sweetened yoghurt containing chocolate pieces thus obtained is metered into uncontaminated pots under a laminar flow hood (conventional yoghurt process) and can be conserved (without preserving agents) for up to 30 days at a maximum of 10 0 C.
• the sweetened aqueous preparation containing chocolate pieces is stored for 3 weeks at 1O 0 C, and then metered as superimposed bilayers (therefore without mixing) into a pot :
• the flavored sweetened yoghurt containing chocolate pieces thus obtained is metered into pots, and can be conserved (without preserving agents) for up to 30 days at a maximum of 1O 0 C.
• composition of the chocolate is given in table 10 below:
• the cocoa mass contains, as % by weight: 1.7% of water, 53.4% of fat and 44.95% of dried defatted cocoa; the water content thereof is ⁇ 1%, the particle size thereof is fine
• the dark chocolate contains, as % by weight: 0.5% of water, 27.7% of fat (of which approximately 0.3% lecithin) , 22.3% of dried defatted cocoa and 49.5% of sugar; preferably, its particle size using a Palmer is ⁇ 30 ⁇ m.
• these two constituents and the cocoa butter are sold by the company Barry-Callebaut .
• the initial natural mold and yeast contamination of this chocolate is 75 cfu/g.
• the preparation of the chocolate is carried out in the following way:
• Blocks of 25 kg of solid cocoa butter (2O 0 C) are melted in the closed tank (10), the double-walled jacket being supplied with steam at 100-110 0 C so as to accelerate the melting.
• the other solid ingredients (chocolate, cocoa paste) , purchased as "easy melt” (chips, or pieces typically of 1 to 30 g) , are melted into the cocoa butter at approximately 100 0 C and the double-walled jacket is regulated at 75 0 C.
• the stirring maximum
• the tank (10) is closed, the pump (17) starts up so as to provide circulation in the pipeworks A and C, and the chocolate, subjected to maximum stirring, is brought to 100 0 C by heating via the double-walled jacket supplied with steam (vapor pressure 110 KPa in absolute pressure) .
• the tank (10) is opened to the air by means of a vent (13) via a sterile filter so as to eliminate the steam.
• the tank (10) is then closed again and is placed under a nitrogen pressure (12) via a sterile filter, the pressure being regulated at 120 KPa in absolute pressure until the production of the next batch, so as to prevent any entry of gas or of material from the outside which could recontaminate the pasteurized product.
• the chocolate is then immediately cooled to 33 0 C by regulation of the water inlet into the double-walled jacket, and is maintained at 33 0 C until use (within 24 h) .
• the taste of the chocolate has not been substantially modified by the pasteurization.
• the residual contamination measured by the same method as in example 1, is less than 1 cfu/300 g, i.e. a decrease of 4.3 log.
• the chocolate is cooled on line to 26 0 C on a scraped surface heat exchanger (20), and is then injected into the sweetened aqueous preparation (same formula as example 1) at -2°C, via a 6.5 mm nozzle (insulated by a double-walled jacket at 28 0 C) , in a crystallization tube that has a double-walled jacket and an internal diameter of 8 mm.
• the double-walled jacket is supplied with ice-cold water at -2 0 C. At this stage, there is 75% by weight of chocolate and 25% by weight of sweetened aqueous preparation.
• a cylinder of chocolate 6.9 mm in diameter is formed at the center of a ring of sweetened aqueous preparation, and the time taken to pass through the crystallization tube is 181 s, for a chocolate flow rate of 6 kg/h.
• the cylinder of solidified chocolate is cut by the shearing of the blades of a centrifugal pump used as a dynamic mill.
• the speed of rotation is adjusted so as to obtain chocolate "cylinders" that are approximately 8 mm long. It is also possible to increase the number of blades (usually 2 spokes) up to 10 spokes, so as to reduce the speed of rotation.
• Additional sweetened aqueous preparation at 4 0 C reaches the centrifugal pump, at a flow rate of 44 kg/h, and mixes with the chocolate pieces, which gives a sweetened aqueous preparation containing 12% by weight of chocolate pieces.
• the mixture is stored in mobile containers, conserved for up to 3 weeks at 4 0 C.
• a flow rate of 132 kg/h of sweetened aqueous preparation could be mixed in the centrifugal pump with the solidified chocolate originating from 3 crystallization tubes, each at 6 kg/h.

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• Confectionery (AREA)

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• 2005
  • 2005-10-24 WO PCT/IB2005/003556 patent/WO2006046147A1/en active Application Filing
  • 2005-10-24 EP EP05806090A patent/EP1833303A1/de not_active Withdrawn

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