EP3107405A1

EP3107405A1 - Edible multicoloured, fat-based, solid oral compositions and the manufacturing process thereof

Info

Publication number: EP3107405A1
Application number: EP15709427.7A
Authority: EP
Inventors: Alessandro Bottini; Claudia CAPPELLETTI
Original assignee: Perfetti Van Melle SpA
Current assignee: Perfetti Van Melle SpA
Priority date: 2014-02-21
Filing date: 2015-02-18
Publication date: 2016-12-28
Also published as: WO2015124642A1; RU2016133687A; RU2688817C2; RU2016133687A3

Abstract

The present invention relates to a manufacturing process for edible fat-based solid oral compositions, characterised by the presence of a plurality of colours on a hollow multicoloured body defined by the union of two or more portions, and the solid oral compositions obtainable by means of said process.

Description

EDIBLE MULTICOLOURED, FAT-BASED, SOLID ORAL

COMPOSITIONS AND THE MANUFACTURING PROCESS THEREOF

DESCRIPTION

The present invention relates to a process for the preparation of edible multicoloured fat-based solid oral compositions, and the solid oral composition obtainable by said process.

Prior art

Processes for obtaining fat-based solid oral compositions are already known. In particular, solid oral compositions have been made wherein the fatty base consists of chocolate. US 3961089 discloses a method for obtaining chocolate eggs characterised by the fact that they have a certain external colour and optionally a different internal colour. Each layer can also have a distinctive flavour but, as the layers adhere to one other over the whole surface of the egg thus formed, consumers are obliged to eat both layers simultaneously, and therefore to perceive a mixture of flavours that may not appeal to them. The process described also has a further drawback, namely the need to eliminate the surplus fatty mass poured. According to the prior art, such excesses are recycled in production after suitable heat treatments, such as chocolate tempering. This aspect, as well as requiring energy, also requires masses with different compositions, if only different colours, to be poured in separate steps, so that the surpluses are not mixed, in which case they could not be recycled.

GB207974 suggests a different technology, which does not involve the need to pour and recycle surplus chocolate, and is based on the use of a plunger core, rendered non-stick with solvents, which is immersed in the mould into which the chocolate was poured. This technology was improved by EP0589820, which uses a cooling member at a temperature below 0°C, designed to be immersed in the cavity with chocolate, thus eliminating the need for solvents. However, a small surplus of chocolate is still poured in both cases, which forms flashing on the edge of the cavity after immersion of the cooling member. It is reported that the use of this technology, known in the field as "cold fmger", "frozen cone" or "fast shell", is independent of the viscosity of the poured mass.

WO9532633 discloses the use of the cold fmger technology in the production of multilayer solid oral compositions. By using suitable techniques, an outer surface with differently-coloured masses can be obtained; however, the inner surface of the shell necessarily consists of a single material, due to the fact that different masses have to be poured into the same cavity at two different times. After each mass is poured, it must be formed by inserting a cold fmger of suitable dimensions, bearing in mind that the thickness of the portion made changes with each pouring.

There is consequently still a need for a process that produces solid oral compositions consisting of fatty masses with different colours and flavours in a single pouring step, said masses being clearly distinct from one another.

Moreover, hollow figures obtained by joining two or more portions, wherein sub-portions characterised by areas of different colours in which said same colour is visible both from the outside and the inside are clearly identifiable, are not available. Products of this type are particularly desirable for their added aesthetic value. Consumers can also enjoy a novel sensory experience by eating the various regions together or separately, especially if they are combined with different flavours or colours.

Description of the invention

A process has been found for producing hollow solid oral compositions by joining two or more separately formed distinct portions, consisting of fat-based foodstuffs and characterised in turn by sub-portions of different or alternating colours which are clearly distinguishable from one another. Said process, in its most specific form, comprises the following steps:

a) preparing at least two fat-based edible masses, each of which has a different colour from the others;

b) providing a first mould, comprising one or more cavities;

c) simultaneously pouring into each cavity a known quantity of said at least two fat-based edible masses through separate nozzles for each mass;

d) subjecting the mould to vibration for a time ranging from 1 to 120 s without mixing the masses in the cavities with one another;

e) in each cavity immersing in the poured mass, consisting of said two masses, a cooling member at a temperature of less than 0°C, so as to define in each cavity a known volume between the outer surface of the cooling member and the inner surface of the cavity, said volume being filled by the two edible fatty masses due to the immersion of the plunger that pushes them towards the walls and edge of the cavity, maintaining a clear separation of linear appearance between them;

f) maintaining each cooling member in position for a time ranging from 1 to 30 s, thus cooling a thin layer of the poured mass which comes into contact with said cooling member;

g) removing each cooling member from each cavity wherein a portion has been defined that consists of a single layer comprising two or more sub-portions of different colours, clearly distinguishable from one another, each of which occupies a clearly defined area;

h) repeating steps a) to g) using two fatty masses different from or the same as to those used in step a) and a second mould;

i) cooling both moulds comprising the cavities with the portions obtained for times ranging from 10 to 60 minutes at temperatures ranging from 1 to 15°C; j) heating the edge of the portions present in the cavities of at least one of the two moulds;

k) joining the two moulds by sealing the overlapping edges of the portions; 1) subjecting the moulds, joined bookwise, to a second cooling step for times ranging from 5 to 120 minutes, at temperatures ranging from 1 to 20°C; m) demoulding the hollow solid oral composition resulting from sealing the two portions.

It was then found that the two fat-based masses remain separate from one another, forming distinct sub-portions of the single portion defined in each cavity, despite some operations liable to cause mixing, in particular the vibration at step d) and the immersion of the piston at step e). In particular at the vibration step, despite the movement and the energy transmitted to the two masses, the two poured masses of step a) form a single body, characterised by a well-defined boundary between them; any air present is expelled, and the two masses settle at the base of the cavity, presenting a substantially flat surface towards the edge thereof. At the subsequent step of immersion of the cooling member, the masses are pushed upwards, filling the space between the cooling member and the upper edge of the cavity. Despite this movement they remain separated from one another by a well-defined boundary.

In this way, a single pouring step produces a portion of solid oral composition characterised by differently coloured regions which are clearly separate, and wherein different colours are visible both internally and externally.

A series of other portions was then made in a second mould by repeating steps a) to g). If the two fatty masses of step h) are characterised by different colours from the masses of step a), the portions of the second mould will be clearly distinguishable from the portions of the first mould. However, if the colours of the masses of step h) are identical to those of step a), it is preferable for the nozzles of step 1) to be positioned so as to pour the masses into different positions in each cavity from the pouring positions of step c).

In this way, a hollow solid oral composition is formed in steps j)-l) by joining two distinct portions, characterised by sub-portions on the inner and outer surface thereof, all of which said sub-portions are of different colours or alternating colours, which are clearly distinguishable and separated by clear demarcation lines between one colour and another, namely without shading, preferably of linear appearance. "Linear appearance" here means that the demarcation line between two sub-portions, when observed perpendicular to the cavities, appears substantially straight.

When the process is carried out on an industrial scale, the first and second moulds are preferably positioned consecutively on a transport device such as a conveyor belt or chain. The movement of the device conveys the moulds, preferably traversing them, under the nozzles, thus defining a direction of movement of the moulds. The nozzles of steps c) and 1) are preferably aligned parallel or perpendicular to the direction of movement. Said nozzles are preferably positioned symmetrically to the centre of symmetry of each cavity when the mould is positioned for pouring.

The time of step i) preferably ranges from 20 to 60 minutes, most preferably from 30 to 40 minutes. The temperature preferably ranges from 2 to 13°C, most preferably from 3 to 10°C.

Steps e), f), g) and i) are advantageously carried out under controlled air temperature and humidity conditions; it is therefore appropriate to restrict the spaces wherein said operations are performed and provide suitable air blowing and conditioning systems, as it is important to ensure that condensate does not form on parts of the machinery or parts of the edible masses. At steps e), f), g) and i) the air humidity is preferably below 20% H and the temperature is preferably from 0 to 20°C, more preferably from 10 to 18°C.

It is therefore advantageous to insert the following step next:

n) inserting an inedible article or a foodstuff into the cavities of one of the two moulds with the portions formed as desired.

The hollow solid oral compositions can be eaten as they are, can form the exterior of a product containing a foodstuff with a filling function, or can contain an inedible article. The filling can preferably comprise chocolate, chocolate substitute, creams, sugar, fondant, frappe, milk derivatives, peanut butter, vegetable fats, fruit, hazelnuts, pistachio nuts and combinations thereof.

Alternatively, the solid oral composition thus formed can contain an inedible article. Said inedible article is preferably a small toy contained in a protective shell. Other inedible articles used in step n) can be, for example, collectable characters, playing cards, promotional points, competition coupons, cards with phrases, tattoo transfers, stickers and combinations thereof.

The edible masses must fill the space between the cooling member and the cavities exactly up to the edge thereof, not remaining under or protruding from the cavity edge, so that no waste is generated.

This is achieved by ensuring that no surplus is poured which would have to be eliminated by inverting the moulds, as in the conventional manufacturing technique used, for example, to produce chocolate egg shells. Waste can be avoided by pouring amounts of fatty mass that precisely fill the space between the surface of the cavity and the surface of the cooling member.

Said space or volume is defined on each occasion by the geometry of the cavity, the geometry of the cooling member and the extent to which the cooling member is immersed in the cavity; it therefore varies according to the shape and thickness of the portion to be obtained. When said volume has been defined, the total of the masses poured into the cavity can be determined by pouring systems, which volumetrically measure out the same total amount as the two masses or, when the weight has been determined on the basis of the density of the masses, by gravimetric systems. When the total volume or weight of the two masses to be poured has been defined, it is preferable for it to vary by less than ± 5% by weight or volume, more preferably less than ± 1%, and most preferably less than ± 0.5%.

In this way surpluses of the two fatty masses are not poured, the production of flashing on the mould surface is avoided, and the edge of the two masses is flush with the cavity edge, which facilitates closing and production of the solid oral composition consisting of the two portions pre-formed in the mould cavities. Step k) can be closed bookwise or closed by rapidly inverting one mould and immediately placing it on the other, preferably with subsequent pressure by a cooling member, optionally vibrating, to ensure complete closing of the hollow solid oral compositions.

Elimination of waste is an advantageous aspect of the invention. In the traditional production of solid oral compositions of fat-based foods consisting of a single foodstuff, such as a layer of milk chocolate, waste can be recovered and recycled, even continuously, because once it has been melted or retempered it can be poured into further cavities.

The same applies to multi-layer solid oral compositions wherein the first layer is poured and solidified before the second is poured, thus allowing waste from the two poured masses to be recycled separately.

Conversely, in the present process, at least two different masses are poured simultaneously into the same cavity, and sealed along a demarcation line, so that any surplus poured or flashing on the mould would inevitably consist of a mixture of the two masses, and would be impossible to recycle, because it would have a different colour, flavour, and other ingredients from each starting mass poured.

This problem would be further exacerbated if portions were to be made with sub-portions all of which have different colours, optionally making solid oral compositions all with different colours.

In fact it is preferable to obtain a foodstuff according to the present process wherein the masses of step a) are not the same as the masses of step h).

It is particularly preferable for the foodstuff obtainable from the present process to consist of masses of the same weight and dimensions; consequently, in view of the need to avoid waste, it is preferable for the single masses of steps a) and h) to have the same weight, with a maximum tolerance of ± 0.1 g, more preferably ± 0.05 g, and most preferably ± 0.02 g.

The process according to the invention can also include a further step wherein the products obtained from step m) are wrapped in a wrapping which indicates that it contains a foodstuff consisting of differently-coloured sub-portions.

The process according to the invention is preferably implemented by controlling the viscosity of the poured masses, unlike the prior art using cold finger technology; it is preferable for the masses at step c) to have a minimum viscosity at 40°C of 100 cps and a maximum viscosity of 20000 cps.

It is also preferable for the masses at step c) to have viscosities that differ by less than 10% (calculated on the higher viscosity).

In order to prepare the two poured masses for immersion of the cooling member, it is preferable for the moulds at step d) to be vibrated for 1 to 120 seconds, at a frequency of 500 to 50 Hz and an amplitude of 5 to 0.1 mm. The vibration frequency preferably ranges between 200 and 80 Hz, and most preferably between 150 and 100 Hz. The vibration amplitude preferably ranges between 2 and 0.5 mm, and more preferably between 1.7 and 1 mm.

It has now surprisingly been found, apparently counter- intuitively, that the different masses poured into each cavity do not mix together at this step, but remain separated by a well-defined demarcation area, and also form a flat upper surface, which allows the space between the cavity and the cooling member to be filled precisely, thus facilitating the positioning of the edge of the portion flush with the edge of the cavity.

It is also preferable for the cooling members of steps e) and n) to have a temperature ranging from -30°C to -5°C, more preferably from -10°C to -25°C, and most preferably from -15°C from -22°C.

At least 90% by weight of said fat-based edible masses, more preferably at least 96%, and most preferably at least 99% by weight, consists of chocolate, chocolate substitute or combinations thereof.

The masses of steps a) and h) can be tempered, for example if they consist mainly of chocolate or chocolate substitutes that require tempering. Food colourings, plant derivatives, flavourings, acidifiers, water and inclusions can advantageously be added to each of the masses, independently of one another.

Solid oral compositions made with a plurality of layers of different fatty masses, such as the traditional surprise eggs with a brown exterior and white interior, are made by successive pourings at different pouring stations. However, the Applicant has found that a single pouring operation per mould can be effected by using a single pouring station fitted with four or more pouring nozzles per cavity, each nozzle being dedicated to pouring one of the edible masses of steps a) and h). The first and second moulds are traversed with a conveyor device to position them sequentially under the pouring station.

Preferably, two or more pouring nozzles operate simultaneously, pouring the edible masses of step a) into the cavities of the first mould, and subsequently, the other nozzles simultaneously pour the edible masses of step h) into the cavities of the second mould.

The product obtainable by the process described is therefore a hollow solid oral composition, formed by fat-based masses, preferably based on chocolate or chocolate substitute, advantageously characterised by a different colour, clearly separated from each other, forming distinct sub-portions of the solid oral composition obtained.

Said foodstuff can in turn be inserted in a hollow solid oral composition consisting of fat-based foods.

The product is therefore a novel food product which offers a novel combination of shapes and colours and the possibility of combining different flavours, thus offering new possibilities to meet growing consumer demand.

Said fat-based foodstuff consists of a hollow body consisting in turn of two solid oral portions and comprising three or more sub-portions consisting of masses coloured differently from one another, or coloured alternately, which occupy regions characterised by well-defined borders between one region and another, wherein the regions are identifiable from both the outside and the inside of the hollow figure, as they are positioned adjacent to one another in a single layer.

It is preferable for the sub-portions and the above-mentioned corresponding regions to be four in number, and for them to be coloured differently from one other, as schematically illustrated in Figure 1. Alternatively, the coloured regions can have two different colours arranged alternately as schematically illustrated in Figure 2, wherein a and al represent brown sub-portions and b and bl represent white sub-portions. Sub-portions "a" and "b" represent a first single-layer portion, and sub-portions "al" and "bl" represent a second single-layer portion.

The foodstuff is also preferably characterised by the possibility of manually separating said regions into groups and/or individually, by breaking them along predetermined score lines. The score lines can derive, as preferred, from the sealing lines of the two portions that constitute the hollow body, join lines of different masses, indentations on the inner or outer surface of the hollow figure, and/or combinations thereof.

This possibility constitutes an improvement on the system used for the current products in the same category offered on the market, as in the case of multilayer products, the various regions are not separable from one another in view of the large area of contact between them. Conversely, in the product according to the invention the masses are arranged in a single layer, so the join between the various regions is equivalent to the thickness of the hollow body, which makes separation easier. Consumers can therefore eat the product whole or separated into its constituent regions, in the order they prefer. As will be illustrated below, the various masses can also differ in terms of other organoleptic properties such as flavour, acidity, etc., which means that consumers have access, in a single product, to a combination of multiple flavour experiences.

The compositions according to the invention are preferably less than 5 mm thick, and more preferably less than 3 mm thick. In particular, a mean thickness ranging between 1.5 mm and 2.1 mm is preferred.

The masses that make up the foodstuff according to the invention preferably consist of at least 90%, more preferably at least 96%, and most preferably at least 99% by weight of chocolate, chocolate substitute or combinations thereof. One or more masses preferably consist entirely of one of the varieties of chocolate.

Moreover, each sub-portion and corresponding region of the solid oral composition is preferably characterised independently of the others by the presence, as desired, of different colours, plant derivatives, flavours, acidity, inclusions, quantity of water and combinations thereof.

The colour of each region can be that of the mass of which it consists, such as white for white chocolate, dark brown for dark chocolate, etc., or can be imparted or influenced by the addition of colourings. The preferred colourings are food colourings supported on a fatty base. The colouring formulations on a fatty base are preferably contained in a percentage lower than 2%, more preferably lower than 1 %.

The preferred flavourings are fat-soluble flavourings, regardless of the flavour they impart. All flavourings can be used, in particular fruit and berry, nut, spices, mint and combinations thereof. Less than 1% of the flavouring is preferably contained in each region, more preferably less than 0.7%, and most preferably between 0.6% and 0.1 %.

Each sub-portion can alternatively be characterised by its own flavour, depending on the foodstuff that constitutes its main ingredient. For example, sub-portions and the corresponding regions with white chocolate, milk chocolate, dark chocolate and gianduia flavours and combinations thereof can be present.

Food acids, optionally buffered with salts thereof, can also be added to each mass, and therefore to each sub-portion and corresponding region, independently of the others. The food acids can be selected from citric, malic, lactic, tartaric, adipic, fumaric and acetic acid and combinations thereof. The total acids and salts thereof are preferably added in the amount of from 1% to 0.01% by weight of each region, more preferably from 0.7% to 0.02%, and most preferably from 0.4% to 0.04%.

Each sub-portion can contain an amount of added water, preferably ranging from 0.2% to 0.005%, and more preferably from 0.1% to 0.01%.

Each sub-portion and corresponding region can also contain inclusions, preferably selected from chopped walnuts, hazelnuts, almonds, peanuts, cocoa, dried fruit, biscuits, toasted cereals, puffed cereals, puffed rice, and confectionery products in granulated form.

The combination of said elements (colour, flavour, acidity and inclusions) contributes to making each sub-portion and corresponding region unique and distinguishable from the others.

Specific combinations of colour and flavour that reproduce the natural combination of a food, such as a fruit or a type of chocolate, are also preferred, because they reinforce the sensory perception. For example, a pink region can advantageously include a strawberry flavouring; conversely, a milk-chocolate flavoured region will advantageously have a light brown colour. In this way the sensory experience of the consumer, who may eat the product as it is or divide it into regions or groups of regions, is further enriched.

It is preferable for the foodstuff obtainable from the process to consist of regions of the same size, and therefore the same weight; the individual masses that make up the corresponding regions therefore preferably have the same weight, with a maximum tolerance of ± 0.1 g, more preferably ± 0.05 g, and most preferably ± 0.02 g.

The foodstuff according to the present invention can also advantageously contain an edible filling or an inedible article.

The foodstuff described so far can in turn be inserted into a hollow solid oral composition consisting of fat-based foods. Examples

Example 1 (invention)

Hollow spherical body:

^■ Diameter 5.5 cm

^■ Thickness: 1.8 mm

^■ Layers deposited: single layer

^■ External appearance: four segments of different colours that divide the sphere into four equal regions.

Each segment consists of a mass having the following composition:

Segment 1 Segment 2 Segment 3 Segment 4

(yellow) (purple) (white) (red)

Ingredients % % % %

White chocolate

99.55 98.30 99.44 99.07 substitute

mixture of citric, lactic

0.05 0.20

and malic acid

water 0.15 0.18 0.10 0.13 oil-soluble paprika 0.15 0.10 oil-soluble cochineal 0.80 0.40 vanilla flavouring 0.46

cinnamon flavouring 0.30 apple flavouring 0.10

raspberry flavouring 0.52

Total 100.00 100.00 100.00 100.00

In the above description and the following claims, the terms:

- "(solid oral) compositions", "foods", foodstuffs" and "edible products" shall be deemed to be synonymous;

- "cooling member" shall mean a cooling element having an outer surface that preferably matches the inner surface of a mould cavity.

The invention is obviously not limited to the particular embodiments described above; numerous modifications of detail can be made which are within the reach of the skilled person, while still remaining in the ambit of the innovation, as defined in the annexed claims.

Claims

1. Process for producing hollow solid oral compositions obtained by joining two distinct, separately formed single-layer portions consisting of fat-based foods which, in turn, comprise two or more sub-portions of different colours, which said process comprises the following steps:

a) simultaneously pouring into each cavity of a first mould a measured amount of at least two fat-based edible masses of different colours by means of separate nozzles for each mass;

b) subjecting said first mould to vibration in order to level the masses present in each cavity without mixing them;

c) immersing a cooling member with a temperature below 0°C in the masses poured into each cavity for a time ranging between 1 and 30 sec so as to form and cool a thin layer of the poured edible masses between the outer surface of the cooling member and the inner surface of the cavity, wherein said masses maintain a definite separation between them;

d) removing each cooling member from its cavity wherein a single-layer portion consisting of at least two sub-portions of different colours has been formed; e) repeating steps a) to d) in a second mould using at least two fatty masses which are different from or the same as those used in step a);

f) subjecting both moulds to a first cooling step;

g) heating the edge of said single-layer portions present in the cavities of at least one of the two moulds;

h) joining the two moulds by sealing the overlapping edges of said single-layer portions;

i) subjecting the joined moulds to a second cooling step;

1) extracting from the moulds the hollow solid oral composition resulting from sealing the two single-layer portions.

2. Process as claimed in claim 1, wherein said mould- vibration step b) has a duration ranging from 1 to 120 seconds, with a frequency of 500 to 50 Hz and an amplitude of 5 to 0.1 mm.

3. Process as claimed in claim 1 or 2, wherein said first mould-cooling step f) takes place at a temperature of between 1 and 15°C for a time of between 10 and 60 minutes.

4. Process as claimed in claim 1 , 2 or 3, wherein said second mould-cooling step i) takes place at a temperature of between 1 and 20°C for a time of between 5 and 120 minutes.

5. Process as claimed in any one of the preceding claims, wherein at 40°C said fat-based edible masses have a minimum viscosity of 100 cps and a maximum viscosity of 20000 cps, said viscosities differing by less than 10% at the pouring step.

6. Process as claimed in any one of the preceding claims, wherein said edible masses have the same weight with a tolerance of ± O. lg.

7. Process as claimed in claim 1, wherein said cooling member used in step c) has a temperature of between -30°C and -5°C.

8. Process as claimed in any one of the preceding claims, wherein at least 90% by weight of said fat-based edible masses consists of chocolate, chocolate substitute or combinations thereof.

9. Process as claimed in claim 8, wherein one or more of the following is added to each one of the masses independently of the others: food colourings, vegetable derivatives, flavourings, acidifiers, water and inclusions.

10. Process as claimed in any one of the preceding claims, wherein said pouring step is carried out at a single pouring station, the edible masses being poured sequentially into said first and second moulds which are caused to traverse by a transport device, said pouring station comprising at least four pouring nozzles per cavity, each nozzle being dedicated to pouring one of the edible masses of steps a) and e).

1 1. Process as claimed in claim 10, wherein two or more pouring nozzles operate simultaneously, pouring the edible masses of step a) into the cavities of the first mould, after which the other nozzles simultaneously pour the edible masses of step e) into the cavities of the second mould.

12. Process as claimed in any one of the preceding claims, wherein said measured amount of edible fatty masses poured into each mould cavity is such as to fill the space between cooling member and cavity precisely up to the edge thereof during step c), without overflowing, so as not to generate mould flashing that requires reprocessing.

13. Process as claimed in claim 1, wherein said first mould-cooling step f) is followed by the step of:

m) inserting an inedible article or a foodstuff into the cavities of one of the two moulds with the single-layer portions of solid oral compositions.

14. Process as claimed in any one of the preceding claims, also including the step of:

n) wrapping the resulting hollow solid oral compositions in a wrapping which reveals that it contains a foodstuff consisting of differently coloured sub- portions.

15. Fat-based edible composition obtainable by the process as claimed in any one of claims 1-14, consisting of a hollow body comprising two single-layer portions, each of which portions comprises two or more sub-portions consisting of differently coloured masses that occupy regions characterised by clear boundaries between one region and the next, wherein said regions are identifiable from both the outside and the inside of the hollow body, and arranged adjacent to one another in a single layer.