RU2836324C1 - Method for production of chocolate product (embodiments) and chocolate product - Google Patents

Abstract

FIELD: food industry.

SUBSTANCE: invention relates to confectionary industry. Proposed is a method for production of a chocolate product involving production of material obtained from a cocoa-based substrate. Method involves treating a cocoa-based substrate with at least one enzyme selected from amylases, wherein the cocoa-based substrate is selected from cocoa powder and/or cocoa mass. Method also involves treating cocoa flesh with at least one enzyme selected from at least one cellulase and/or at least one pectinase. Method involves mixing cocoa pulp and a cocoa-based substrate. Then the dried product is dried and mixed with cocoa butter. In another embodiment, the method for production of a chocolate product involves additional mixing with ingredients selected from a group containing sugar, an emulsifier, milk-based ingredients and flavor additives and mixtures thereof. Also disclosed is a chocolate product produced by said method, containing cocoa butter and 20.0 wt.% to 90.0 wt.% of a mixture of cocoa pulp treated with an enzyme and a cocoa-based substrate treated with an enzyme.

EFFECT: invention is aimed at improving the consistency of the product and the process by fermentation and/or enzymatic hydrolysis of the paste, and not individual beans (reducing the number of poorly fermented beans); providing controlled fermentation of paste with specific controlled microorganisms; reduced contamination, since the cocoa shell is not subjected to fermentation and drying in potentially unsuitable conditions; increased content of fibers in chocolate products in a controlled manner within the framework of a more orderly process and more homogeneous conditions of drying and roasting due to removal of individual beans from the process.

13 cl, 3 dwg, 12 ex

Description

The present invention relates to the field of new chocolate-like products and chocolate products, new ingredients for use in said products and to uses of the new ingredients.

Prerequisites for the creation of an invention

Although it is well known that the cocoa plant is harvested to produce cocoa seeds, which are used to produce cocoa liquor, cocoa butter, and cocoa powder, other parts of the cocoa pod are not used.

The cocoa pod consists of the husk, pulp, and cocoa beans. The pulp is the aromatic, moist substance that surrounds the beans.

During the initial processing of cocoa beans, the pulp is typically removed through fermentation and hydrolysis by microorganisms. The hydrolyzed pulp is known in the industry as "restoration". During fermentation, the pulp provides a substrate for the various microorganisms needed to produce the chocolate flavor precursors that are fully developed later during the roasting process. Although pulp is necessary for fermentation, there is often more pulp than is required.

The excess pulp was used to obtain cocoa gel, alcohol and vinegar, nata and processed pulp. Controlled fermentation and distillation from the aging can produce an alcohol essence containing more than 40% ethanol. The resulting alcohol can be further fermented to produce acetic acid.

Cocoa lees have been shown to be a suitable substrate for fermentation to produce nata, a product typically obtained from the fermentation of coconut milk.

Raw cocoa pulp is also used to make smoothies and other so-called "healthy" drinks. However, the composition and availability of the pulp affects its commercial suitability.

The applicant provides a means for more efficient use of this material in a food product, in particular in a chocolate product, production in WO 2019115731, WO 2019115735 and WO 2019149909.

EP 3114939 and EP 3114941 mention the possibility of using cocoa pulp as a sweetener. However, these documents do not actually disclose the methods of such use. These documents also refer to the specific three-phase separation variant that constitutes the traditional method of making chocolate, and not to the combined process described below.

FR 2828379 relates to the use of cocoa husks in nutritional compositions, not the contents of the beans.

US 4331692 relates to the use of cocoa pulp after separation from the rest of the legume and food products containing this material.

The present invention is directed to providing methods and products that utilize other parts of the fruits of plants of the genus Theobroma. These products and methods provide advantages in terms of the rational use of resources. In addition, the present invention provides methods that will allow potential ingredients in these plants to become commercially viable.

In addition, the invention provides completely new products that are endowed with new organoleptic properties. In particular, the processing allows increasing the sweetness of cocoa mass alternatives and maintaining the technological suitability of such products for processing into chocolate.

The present application also allows for better control over the fermentation process in producing these new compositions by combining a portion of the seeds at controlled stages during the fermentation and manufacturing process.

Thus, the present invention makes it possible to solve the problems associated with achieving the following:

● improving product and process consistency through fermentation and/or enzymatic hydrolysis of the paste rather than individual beans (reducing the amount of poorly fermented beans);

● ensuring controlled fermentation of the paste with specific controlled microorganisms;

● reduced contamination as the cocoa shell is not subjected to fermentation and drying under potentially unsuitable conditions;

● increasing the fibre content of chocolate products in a controlled manner within a more streamlined process; and

● more uniform drying and roasting conditions due to the removal of individual beans from the process.

Statement of the essence of the invention

The present invention relates to products that contain a composition obtained from a plant of the genus Theobroma. The present invention also provides new compositions obtained from the pulp of a plant of the genus Theobroma.

The present invention provides the following:

● material obtained from a plant of the genus Theobroma, preferably in the form of a paste,

● a processed, preferably enzymatically processed, derivative of a material,

● fermented derivative of the above materials,

● dried version of the above materials,

● a fried version of the above materials and

● methods for obtaining the above materials.

In a preferred embodiment, the above materials are used as intermediates in the production of a chocolate product composition.

In addition, the present invention provides processes for increasing the sweetness of materials and compositions obtained from Theobroma.

In particular, the present invention provides a process for obtaining a material obtained from a plant of the genus Theobroma, comprising the following steps:

a. grinding of seeds and/or part of seeds of a plant of the genus Theobroma, optionally in the presence of the following components:

i. pulp and/or pulp extract of a plant of the genus Theobroma and/or

ii. the non-pulpable, seedless portion of the fruit of a plant of the genus Theobroma,

b. if both i. and ii. are not present in step a., mixing the product of step a. with each or both components of i and/or ii.

The present invention may also preferably include a step of fermenting the above-described mixture.

In addition, the present invention provides a composition obtained by the above process.

This product may be preferably described as an alternative to traditional cocoa mass/liquor, since the product is obtained from the seeds of the genus Theobroma, but also preferably includes sugars from the pulp and/or non-pulp and seedless portion of the fruit.

The present invention preferably provides a chocolate product, preferably without added sugar, which comprises a composition obtainable from the composition of the present invention.

The present invention provides advantageous properties in terms of reducing or completely eliminating added sugar, wherein the sweetness is provided by a natural source, which preferably also contains other components of the cocoa pod that influence the flavor properties of chocolate.

In addition, the present invention provides a means for increasing the sugar content of Theobroma fruit components.

Accordingly, the present invention provides an alternative to the addition of sugars by providing natural sugars that are present in the source - cocoa mass, cocoa butter and/or cocoa powder.

In addition, the present invention provides the use of a by-product of the chocolate manufacturing process, which is usually discarded. Thus, the present invention provides advantages in terms of reasonable use of resources and/or differentiation of flavor properties.

In an embodiment, the components in the mixture are hydrolyzed, preferably enzymatically, to reduce the content of polysaccharides. In an embodiment, the treatment of the mixture may increase the content of mono- and/or di- and/or oligosaccharides.

The enzyme treatment may result in an improved taste sensation of the chocolate product, preferably the chocolate containing the composition of the present invention.

In an embodiment, the treatment of the pulp or pulp extract in a mixture with an enzyme reduces the viscosity of the pulp or pulp extract. This aspect of the invention provides advantages in terms of processing the composition to produce products and/or removing any possible undesirable organoleptic properties caused by the use of too viscous raw material.

In particular, the present invention provides compositions, methods and uses described in the claims.

Description of figures

Fig. 1–3: Flow charts for example processes.

Detailed description

Pulp, seeds, fruits and subsequent mixture

The pulp for use in the present invention is preferably obtained from a plant or plants of the genus Theobroma. The genus of the plant comprises Theobroma angustifolium, Theobroma bicolor (mocambo), Theobroma cacao, Theobroma canumanense, Theobroma grandiflorum (cupuaçu), Theobroma mammosum, Theobroma microcarpum, Theobroma obovatum, Theobroma simiarum, Theobroma speciosum, Theobroma stipulatum, Theobroma subincanum and Theobroma sylvestre. The pulp is preferably selected from cocoa, cupuaçu, mocambo and mixtures thereof, preferably cocoa.

The embodiments described below, which are mentioned in relation to the preferred embodiment of cocoa, are equally applicable to pulp from all other plants of the genus Theobroma.

In the present invention, the term "pulp" refers to the gum-like coating around each bean.

In the present invention, the term "cocoa pulp" also includes dried cocoa pulp, for example in powder form. However, when using the term "dried cocoa pulp", the cocoa pulp is limited to dried cocoa pulp. The source of the cocoa pulp is not particularly limited, and the pulp can be provided by all known varieties of cocoa pods. However, it is preferable to use cocoa pulp with the highest possible sugar content.

In the present invention, the term "extract" has the usual dictionary meaning, i.e., a portion of cocoa pulp containing one or more components of cocoa pulp, wherein one or more components of the original cocoa pulp have been removed in obtaining the extract. In the present invention, any water present in the cocoa pulp is not considered an extract, i.e., the cocoa pulp extract is not water. In an embodiment of the present invention, the cocoa pulp extract is a powder, i.e., the cocoa pulp extract has been dried to remove water.

In the present invention, the term "seed" refers to the normal dictionary meaning of the term, i.e., includes the portion of the fruit pod called the "bean", such as cocoa beans. The seed portion includes the kernel (containing the two cotyledons), the seed coats (husk or husk) and the embryo (germ) or the seed broken into pieces (i.e., not the whole seed).

The seed portion may also optionally contain cocoa bean nibs and/or cocoa shells, preferably these components being obtained by roasting and breaking/winnowing the seeds.

In the present invention, the non-pulp and seedless portion of the fruit includes the remaining portion of the fruit, for example, containing the stalk, placenta, endocarp, mesocarp and/or endocarp, particularly preferably the placenta.

In an embodiment, the embryo components/seed portion and (i) the pulp and/or pulp extract and/or (ii) the non-pulp and seed portion of the fruit may be individually extracted from the fruit and then re-mixed, or the respective fruit portions may be combined and then ground.

For example, the seeds can be completely or partially depulped and then the seeds can be re-mixed with the required amount of pulp and/or pulp extract.

In an embodiment, by individual extraction of the components mixed according to claim 1, any necessary pre-treatments can be carried out. For example, the seeds and/or part of the seeds can be treated with acid or alkali before mixing with the other components, as required in the present invention.

In an embodiment, the pulp and/or pulp extract and/or non-pulp and non-seed portion of the fruit may be processed to reduce the polysaccharide content and/or increase the mono- and/or disaccharide content by the methods described herein prior to combining with the seeds and/or seed portion or processed after combining with the seeds and/or seed portion.

In an embodiment, parts of the components may be added dehydrated and dissolved using water. In an embodiment, the pulp may be processed in any standard manner before combining, for example, it may be filtered, concentrated, pasteurized and/or disinfected, etc.

In an embodiment, the mixture obtained in step a. or step b of the present invention comprises from 1.0 to 80.0 wt.%, preferably from 5.0 to 75.0 wt.%, preferably from 10.0 to 70.0 wt.% and preferably from 15.0 to 65.0 wt.% of pulp, pulp extract and/or pulp- and seed-free portion of the fruit. The percentages mentioned refer to the actual weight of the components, i.e. not based on dry matter, since the pulp may contain a significant amount of water.

In an embodiment, the mixture obtained in step a. or step b of the present invention comprises 0.0 and 80.0 wt.%, preferably from 10.0 to 75.0 wt.%, preferably from 20.0 to 70 wt.% and preferably from 25.0 to 65.0 wt.% of pulp and/or pulp extract, preferably pulp. The percentages mentioned refer to the actual weight of the components, i.e. not based on dry matter, since the pulp may contain a significant amount of water.

In an embodiment, the mixture obtained in step a. or step b of the present invention comprises 0.0 and 80.0 wt.%, preferably from 5.0 to 70.0 wt.%, preferably from 10.0 to 50.0 wt.% and preferably from 15.0 to 55.0 wt.% of the pulp- and seed-free portion of the fruit. The percentages mentioned refer to the actual weight of the components, i.e. not based on dry matter.

The process of the present invention allows the non-seed and non-pulp portion of the bean to be included in the manufacturing process where it can be controlled and processed along with other ingredients, and the seeds can be used. This can provide an increase in the fiber content of the chocolate, which is desirable from a consumer health standpoint, while minimizing the processing complexity of adding a fiber source to the chocolate mass. Adding a fiber source later in the manufacturing process can lead to viscosity and processing issues, but adding it early in the overall process provides increased control and options for subsequent processing to minimize the impact of the addition.

In particular, in a highly preferred embodiment, as mentioned below, the enzymatic treatment of the present invention provides a reduction in fiber content to an extent that ensures processability, but the process of the present invention provides an overall increase in fiber content compared to conventional chocolate. The combined effect of the present invention allows for an increase in the ease with which fiber content can be increased without a corresponding increase in processing complexity.

In an embodiment, the mixture obtained in step a. or step b of the present invention comprises from 20.0 to 99.0 wt.% of the mixture, preferably from 25.0 to 95.0 wt.%, preferably from 30.0 to 90.0 wt.% and preferably from 35.0 to 85.0 wt.% of seeds and/or part of seeds. The percentages mentioned refer to the actual weight of the components, i.e. not based on dry matter.

In a preferred embodiment, the process of the present invention provides for size reduction in step a, which includes a step of grinding, milling, crushing, sifting and/or pulverizing. Such size reduction can be carried out by any device suitable depending on the amount of the mixture processed. On an industrial scale, cocoa bean processing machines can be used.

In a preferred embodiment, the method of the present invention, wherein the size reduction in step a. comprises a size reduction of from 10 to 500 μm, optionally from 20 to 450 μm, optionally to from 30 to 400 μm, preferably from 30 to 250 μm, or from 40 to 150 μm.

In an embodiment, the above particle size refers to d50 (preferably the diameter in which 50% of the mass of particles in the sample have a diameter below this value). The particle size d50 is preferably determined by laser diffraction using a Malvern Mastersizer 2000, Scirocco 2000 method with dry attachment according to the Fraunhofer scattering theory.

In an embodiment of the present invention, process steps a. or b. provide a paste, preferably a paste whose moisture content is in the range of 0.5 to 80% of the mass of the paste.

When forming the paste, the present invention allows for improving the consistency at any stage of fermentation, i.e. eliminating heterogeneity in the mass of cocoa beans and reducing the amount of poorly fermented beans. Removing any contamination with cocoa shells from the fermentable main part also provides advantages in the present invention, i.e. fermentation does not occur near the outer shell. In addition, producing the paste in a controlled environment eliminates any possibility of fermentation occurring in unhygienic places. In addition, producing the paste allows for controlling the addition of, for example, specific microorganisms, technological additives, i.e. they can be added in a controlled manner to obtain a substrate more homogeneous than fermenting beans. This provides additional options for modifying the flavor and aroma properties in a controlled environment.

In a preferred embodiment, the paste contains more than 2.5% by weight of moisture based on the weight of the paste, preferably more than 5% by weight and preferably more than 10% by weight. In a preferred embodiment, the paste contains water in an amount of less than 70% by weight, preferably less than 60% by weight, preferably less than 50% by weight and most preferably less than 40% by weight. For example, from 2.5% to 70% or from 2.5% to 60% and most preferably from 40% to 70%.

In a preferred embodiment, the moisture content, preferably water, is measured using a Karl Fischer analysis, an Orion 2 Turbo with methanol:formamide 2:1, or a halogen moisture analyzer (e.g. a Mettler-Toledo balance).

In a preferred embodiment, the mixture of step a. or step b., preferably a paste, has a sugar content, preferably a mono- and disaccharide content, of more than 3.0 wt.%, preferably more than 5.0 wt.%, preferably more than 6.0 wt.% and preferably more than 8.0 wt.%. In a preferred embodiment, the mixture of step a. or step b., preferably a paste, has a sugar content, preferably mono- and disaccharides, of less than 20.0 wt.%, preferably less than 17.5 wt.%, preferably less than 15.0 wt.% and preferably less than 12.0 wt.%. Preferably from 3.0 wt.% to 20.0 wt.% or from 5.0 wt.% to 15.0 wt.%. The percentages mentioned relate to the actual weight of the components, i.e. not based on dry matter.

Based on the weight of dry matter, in a preferred embodiment the mixture of step a. or step b., preferably a paste, has a sugar content, preferably mono- and disaccharides, of from 10.0 wt.% to 40.0 wt.%, preferably from 15.0 wt.% to 35.0 wt.% and preferably from 17.5 wt.% to 32.5 wt.%.

In a preferred embodiment, the sugar comprises a mixture comprising sugars selected from the group comprising maltose, sucrose, fructose, galactose and glucose, preferably the mixture comprises fructose and glucose. In a preferred embodiment, the sugar mixture of the present invention comprises at least 75% by weight based on the weight of the sugar mixture of a combination of glucose and fructose, preferably at least 80% by weight or at least 85% by weight or at least 90% by weight. In a preferred embodiment, the sugar mixture of the present invention comprises less than 100% by weight based on the weight of the sugar mixture of a combination of glucose and fructose, preferably less than 99.5% by weight or less than 99% by weight or less than 95% by weight. Preferably from 75% by weight to 100% by weight or from 85% by weight to 99% by weight.

In a preferred embodiment, in which the mixture of step a. or step b., preferably a paste, is treated to reduce the polysaccharide content, preferably by the enzymatic treatment described herein, the sugar content is preferably increased compared to the untreated mixture.

In a preferred embodiment, the treated mixture of step a. or step b., preferably a paste, has a sugar content, preferably mono- and disaccharides, of more than 6.0 wt.%, preferably more than 7.0 wt.%, preferably more than 8.0 wt.%, preferably more than 8.5 wt.% and preferably more than 9.0 wt.%. In a preferred embodiment, the treated mixture of step a. or step b., preferably a paste, has a sugar content, preferably mono- and disaccharides, of less than 20.0 wt.%, preferably less than 17.5 wt.%, preferably less than 15.0 wt.% and preferably less than 12.0 wt.%. Preferably, from 6.0 wt.% to 20.0 wt.%, from 7.0 wt.% to 20.0 wt.% or from 8.5 wt.% to 15.0 wt.%. The percentages mentioned refer to the actual weight of the components, i.e. not calculated on a dry matter basis.

Based on the weight of dry matter, in a preferred embodiment the treated mixture of step a. or step b., preferably a paste, has a sugar content, preferably mono- and disaccharides, of from 10.0 wt.% to 40.0 wt.%, preferably from 15.0 wt.% to 40.0 wt.%, preferably from 22.0 wt.% to 35.0 wt.% and preferably from 25.0 wt.% to 35.0 wt.%.

In a preferred embodiment, the mixture of step a. or step b., preferably a paste, has a total dietary fiber content, i.e. insoluble and soluble, of more than 2.0 wt.%, preferably more than 3.0 wt.%, preferably more than 4.0 wt.% and preferably more than 5.0 wt.%. In a preferred embodiment, the mixture of step a. or step b., preferably a paste, has a total dietary fiber content, i.e. insoluble and soluble, of less than 15.0 wt.%, preferably less than 12.0 wt.%, preferably less than 10.0 wt.%, preferably less than 9.0 wt.% and preferably less than 8.0 wt.%. Preferably from 2.0 wt.% to 12.0 wt.% or from 4.0 wt.% to 10.0 wt.%. The percentages mentioned relate to the actual weight of the components, i.e. not based on dry matter.

Based on the weight of dry matter, in a preferred embodiment the mixture of step a. or step b., preferably a paste, has a total dietary fibre content, i.e. insoluble and soluble, of from 5.0 wt.% to 30.0 wt.%, preferably from 10.0 wt.% to 25.0 wt.% and preferably from 12.0 wt.% to 20.0 wt.%.

In a preferred embodiment, in which the mixture of step a. or step b., preferably a paste, has been treated to reduce the polysaccharide content, preferably by the enzymatic treatment described herein, the total dietary fiber content, i.e. insoluble and soluble, has been reduced compared to the untreated mixture or paste. In a preferred embodiment, the content of insoluble dietary fiber is reduced to a greater extent than the content of soluble dietary fiber.

In a preferred embodiment, the treated mixture of step a. or step b., preferably a paste, has a total dietary fiber content, i.e. insoluble and soluble, of more than 2.0 wt.%, preferably more than 3.0 wt.%, preferably more than 4.0 wt.% and preferably more than 4.5 wt.%. In a preferred embodiment, the treated mixture of step a. or step b., preferably a paste, has a total dietary fiber content, i.e. insoluble and soluble, of less than 10.0 wt.%, preferably less than 8.5 wt.%, preferably less than 8.0 wt.% and preferably less than 7.0 wt.%. Preferably from 2.0 wt.% to 10.0 wt.% or from 3.0 wt.% to 8.0 wt.%. The percentages mentioned relate to the actual weight of the components, i.e. not based on dry matter.

Based on the weight of dry matter, in a preferred embodiment the treated mixture of step a. or step b., preferably a paste, has a total dietary fibre content, i.e. insoluble and soluble, of from 8.0 wt.% to 30.0 wt.%, preferably from 10.0 wt.% to 25.0 wt.% and preferably from 12.0 wt.% to 20.0 wt.% or from 12.0 wt.% to 17.0 wt.%.

In a preferred embodiment, the untreated mixture of step a. or step b., preferably a paste, has a total dietary fiber content, i.e. insoluble and soluble, of more than 4.0 wt.%, preferably more than 5.0 wt.%, preferably more than 5.5 wt.% and preferably more than 6.0 wt.%. In a preferred embodiment, the untreated mixture of step a. or step b., preferably a paste, has a total dietary fiber content, i.e. insoluble and soluble, of less than 10.0 wt.%, preferably less than 8.5 wt.%, preferably less than 8.0 wt.% and preferably less than 7.0 wt.%. Preferably, from 4.0 wt.% to 10.0 wt.% or from 5.5 wt.% to 8.0 wt.%. The percentages mentioned relate to the actual weight of the components, i.e. not based on dry matter.

Based on the weight of dry matter, in a preferred embodiment the untreated mixture of step a. or step b., preferably a paste, has a total dietary fibre content, i.e. insoluble and soluble, of from 12.0 wt.% to 30.0 wt.%, preferably from 14.0 wt.% to 25.0 wt.% and preferably from 15.5 wt.% to 20.0 wt.%.

In a preferred embodiment, the treated mixture of step a. or step b., preferably a paste, has an insoluble dietary fiber content of more than 0.25 wt.%, preferably more than 0.5 wt.%, preferably more than 1.0 wt.% and preferably more than 1.5 wt.%. In a preferred embodiment, the treated mixture of step a. or step b., preferably a paste, has an insoluble dietary fiber content of less than 6.0 wt.%, preferably less than 5.0 wt.%, preferably less than 4.0 wt.% and preferably less than 3.0 wt.%. Preferably, from 0.25 wt.% to 6.0 wt.% or from 0.5 wt.% to 4.0 wt.%. The percentages mentioned relate to the actual weight of the components, i.e. not based on dry matter.

Based on the weight of dry matter, in a preferred embodiment the treated mixture of step a. or step b., preferably a paste, has an insoluble dietary fibre content of from 4.0 wt.% to 15.0 wt.%, preferably from 5.0 wt.% to 12.0 wt.% and preferably from 5.0 wt.% to 10.0 wt.%.

In a preferred embodiment, the untreated mixture of step a. or step b., preferably a paste, has an insoluble dietary fiber content of more than 3.0 wt.%, preferably more than 4.0 wt.%, preferably more than 4.5 wt.% and preferably more than 5.0 wt.%. In a preferred embodiment, the untreated mixture of step a. or step b., preferably a paste, has an insoluble dietary fiber content of less than 10.0 wt.%, preferably less than 8.0 wt.%, preferably less than 7.5 wt.% and preferably less than 6.0 wt.%. Preferably, from 3.0 to 10.0 wt.% or from 4.5 wt.% to 7.5 wt.%. The percentages mentioned relate to the actual weight of the components, i.e. not based on dry matter.

Based on the weight of dry matter, in a preferred embodiment the untreated mixture of step a. or step b., preferably a paste, has an insoluble dietary fibre content of from 8.0 wt.% to 25.0 wt.%, preferably from 10.0 wt.% to 20.0 wt.% and preferably from 11.5 wt.% to 17.5 wt.%.

Accordingly, in a highly preferred embodiment, the present invention provides a paste that comprises:

● sugar, preferably mono- and disaccharides, in an amount from 3.0 wt.% to 20.0 wt.%,

● total amount of dietary fiber, i.e. insoluble and soluble, from 2.0 wt.% to 15.0 wt.% and

● moisture in the range of 20.0 wt.% to 80 wt.%, preferably 40 to 70 wt.%.

Accordingly, in a highly preferred embodiment, the present invention provides a processed (preferably enzymatically, as described below) paste which comprises:

● sugar, preferably mono- and disaccharides, in an amount from 6.0 wt.% to 20.0 wt.%,

● total amount of dietary fiber, i.e. insoluble and soluble, from 2.0 wt.% to 10.0 wt.%,

● moisture in the range of 20.0 wt.% to 80 wt.%, preferably 40 to 70 wt.% and

● preferably insoluble dietary fiber in an amount of from 0.25 wt.% to 6.0 wt.%.

Accordingly, in a highly preferred embodiment, the present invention provides a raw paste that comprises:

● sugar, preferably mono- and disaccharides, from 3.0 wt.% to 8.5 wt.%,

● total amount of dietary fiber, i.e. insoluble and soluble, from 4.0 wt.% to 10.0 wt.%,

● moisture in the range of 20.0 wt.% to 80 wt.%, preferably 40 to 70 wt.% and

● preferably insoluble dietary fiber in an amount of from 3.0 wt.% to 10.0 wt.%.

In a preferred embodiment, the mixture obtained in step a. or step b. comprises:

● from 20.0 to 99.0 mass% of seeds and/or parts of seeds, preferably from 30.0 to 75.0 mass% of seeds and/or parts of seeds;

● from 0.0 to 80.0 wt.% of the pulp- and seed-free portion of the fruit, preferably from 0.0 to 20.0 wt.%; and

● from 1.0% by weight to 80.0% pulp and/or pulp extract, preferably from 25.0% by weight to 70.0% pulp and/or pulp extract.

In a highly preferred embodiment, the present invention provides a paste comprising:

● from 20.0 to 99.0% by weight of beans, preferably from 30.0 to 75.0% by weight of beans,

● from 0.0 to 30.0 wt.% of a non-pulp and seedless portion of the fruit, preferably from 2.0 to 15.0 wt.%, and preferably when the non-pulp and seedless portion of the fruit is a placenta; and

● from 10.0% to 60.0% by weight of pulp and/or pulp extract, preferably from 25.0% to 50.0% by weight of pulp.

In a preferred embodiment, the above mixtures/pastes have a moisture content of from 0.5 to 80% by weight of the paste, preferably from 20% to 70% and more preferably from 40% to 65%.

In a preferred embodiment, the mixture of step a. or step b., preferably a paste, has a protein content of more than 2.0 wt.%, preferably more than 2.5 wt.%, preferably more than 3.0 wt.% and preferably more than 4.0 wt.%. In a preferred embodiment, the mixture of step a. or step b., preferably a paste, has a protein content of less than 15.0 wt.%, preferably less than 12.5 wt.%, preferably less than 10.0 wt.% and preferably less than 8.0 wt.%. Preferably from 2.0 wt.% to 15.0 wt.% or from 3.0 wt.% to 10.0 wt.%. The percentages mentioned refer to the actual weight of the components, i.e. not based on dry matter.

Based on the dry matter weight, in a preferred embodiment the mixture of step a. or step b., preferably a paste, has a protein content of from 5.0 wt.% to 24.0 wt.%, preferably from 8.0 wt.% to 18.0 wt.% and preferably from 9.0 wt.% to 15.0 wt.%.

The protein content applies to unprocessed and processed mixtures, i.e., to all embodiments of the present invention.

In a preferred embodiment, the mixture obtained according to the present invention is treated to reduce the polysaccharide content.

In a preferred embodiment, the mixture obtained according to the present invention is processed to increase the content of mono- and/or disaccharides. Such processing preferably increases the sweetness of the mixture, preferably by increasing the amount of monosaccharides, in particular fructose and glucose, preferably glucose.

In an embodiment, the above-described processing steps may be performed separately and individually, or together. Each or both of these processing steps may be performed using an enzyme. In an embodiment, more than one enzyme may be used, optionally enzymes providing multiple functionalities.

The sweetness enhancement is preferably achieved by decomposing polysaccharides, preferably starch, cellulose, hemicellulose and/or pectins, which are present in the seeds, pulp/pulp extract and/or non-pulp and non-seed portion of the fruit. The decomposition is preferably achieved using enzymes.

In a preferred embodiment of the present invention, the treatment of the mixture comprises treatment with an enzyme, the substrate of which may be plant polysaccharides, preferably selected from enzymes including amylases, pectinases, cellulases, xylanases, proteases, preferably class 3 and 4 EC and combinations thereof.

In an embodiment of the present invention, the present invention preferably comprises further treatment with the enzyme glucose (xylose) isomerase (e.g. E.C. 5.3.1.5).

The term "polysaccharide" refers to the dictionary definition of such polymers, i.e. a carbohydrate consisting of a number of molecules linked together, preferably polysaccharides having more than 8 sugar units, more than 10 units or more than 20 units and optionally less than 1000 units or less than 750 units.

The term covers, for example, both hetero- and homopolysaccharides, both linear and nonlinear.

In a preferred embodiment, the reduction of the polysaccharide content means the breakdown of the original polysaccharides, such as the breakdown of pectin, cellulose, etc., into smaller polysaccharides, oligomers and/or di-/monosaccharides. Such breakdown results in a change in the molecular weight distribution of the polysaccharides, i.e. the molecular weight of the polysaccharides is reduced due to the breakdown of larger polysaccharides into smaller compounds.

In an embodiment, the mixture is subjected to enzymatic treatment at a temperature of from 10°C to 80°C, for example, the temperature during enzymatic treatment is from 20°C to 75°C, for example from 30°C to 65°C, from 55°C to 75°C or from 30°C to 55°C.

If multiple (i.e. at least two) enzyme treatment steps are used, the temperature may be varied for each treatment step or remain constant.

In an embodiment, the mixture is exposed to the enzyme for 10 minutes to 72 hours. For example, 10 minutes to 60 hours, 60 minutes to 50 hours, 100 minutes and 40 hours, or 200 minutes to 35 hours.

In an embodiment, the mixture is treated with the enzyme mixture for a period of 1 hour to 7 hours, preferably 2 hours to 5 hours.

If multiple (i.e. at least two) enzyme treatment steps are used, each of the individual steps may be performed within the above time periods and/or the total treatment time is within the above time periods.

The amount of enzyme used depends on the enzyme format (e.g. powder, liquid, etc.), enzyme activity, and mixture composition (e.g. moisture content, seed content, etc.). However, the amounts given below are indicative of the desired amounts.

In an embodiment, the amount of enzyme used is from 10 mg/l to 250 mg/l of cocoa pulp or cocoa pulp extract, preferably from 25 mg/l to 200 mg/l, preferably from 50 mg/l to 150 mg/l.

In an embodiment, the amount of enzyme used is from 1.0 g/l to 200 g/l of the mixture, preferably from 2.0 g/l to 100 g/l, preferably from 5.0 g/l to 50 g/l.

In an embodiment, the amount of enzyme used is from 0.05 ml/kg to 200 ml/kg of the mixture, from 0.1 ml/kg to 200 ml/kg, from 1.0 ml/kg to 200 ml/kg, preferably from 2.0 ml/kg to 100 ml/kg, preferably from 5.0 ml/kg to 50 ml/kg, and more preferably from 5.0 ml/kg to 20 ml/kg or 0.1 ml/kg to 10 ml/kg.

In an embodiment, the amount of enzyme used is from 0.10 to 20% of the mixture, preferably from 0.20 to 10%, more preferably from 0.5 to 5.0%.

The above amounts refer to individual enzymes or to all enzymes present, i.e. the total amount of enzyme used, as applicable.

In an embodiment, the pulp or pulp extract is treated with a pectinase, such as EC 4.2.2.10 (CAS 9033--35--6), EC 3.2.1.15 (CAS 9032--75--1), EC 3.1.1.11 (CAS 9025--98--3), EC 4.2.2.9 or EC 4.2.2.2 (CAS 9015--75--2) or mixtures thereof.

Pectinases are classified with respect to: 1) pectin, pectic acid or oligo-D-galacturonate which is the substrate; 2) whether the cleavage is random (endo-, liquefying or depolymerizing enzymes) or terminal (exo- or saccharifying enzymes); and 3) whether the action is by hydrolysis or transelimination. In a preferred embodiment, the enzyme used is selected from the group consisting of pectinesterases, polymethylgalacturonases (exo- or endo), polygalacturonases (exo- or endo), polymethylgalacturonate lyases (exo- or endo), polygalacturonate lyases (exo- or endo) and protopectinases (e.g. endo-1,5-alpha-L-arabinanase) and mixtures thereof.

In an embodiment, the choice of enzyme and reaction conditions may be optimized for the substrate being processed. For example, it is well known that certain pectinases work optimally at acidic pH, while others work optimally at alkaline pH (e.g., see Table 2, Pectinases: Enzymes for fruit processing industry, International Food Research Journal 21(2): 447–453 (2014), incorporated herein by reference).

In an embodiment, the pectinase has an activity of from 0.50 units to 1.50 units per gram of pulp, such as from 0.75 units to 1.25 units per gram of pulp.

In an embodiment, the pectinase has an activity of from 5.0 units to 50.0 units per gram of pulp, such as from 10.0 units to 30.0 units per gram of pulp.

If required, the enzymes can have an activity from 1000 PGNU/ml to 30,000 PGNU/ml, from 2000 PGNU/ml to 10,000 PGNU/ml, for example from 3000 PGNU/ml to 8500 PGNU/ml.

If required, enzymes can have an activity from 50 PTF to 500 PTF, for example from 60 PTF to 400 PTF.

If desired, the enzymes may have a polygalacturonase activity in the range of 2000 to 20,000 micromol/min/g, such as 3000 to 12,000 micromol/min/g.

The activities of the various pectinases that can be used in the present invention are determined using said known standards. Polygalacturonase unit (PGNU) is defined as the amount of enzyme that produces 1 mg of sodium galacturonic acid under standard conditions (acetate buffer, pH 4.5, 40°C, 10-minute reaction time, 540 nm) per ml of substrate, or as the amount of enzyme required to release one micromole of galacturonic acid from polygalacturonic acid per minute in acetate buffer, pH 4.5, 40°C, and is given in ml or g of enzyme (the latter method is preferably used). Accordingly, pectinesterase unit (PEU) of activity is the amount of enzyme that consumes 1 microequivalent of sodium hydroxide per minute under standard conditions (30°C, pH 4.5). The pectin lyase unit (PLU) is the amount of enzyme that catalyses the cleavage of the linked endo-alpha-1,4-galacturonosidyl (C6 methyl ester) to yield one micromole of delta-4,5-unsaturated product in one minute under the above conditions but at 45°C and pH 5.5. The PTF activity unit corresponds to the enzymatic activity that results in an increase in extraction expressed as a change in optical density of 0.01 after 1 minute at pH 5.8 and 30°C at 235 nm in 0.5% pectin solution.

In an embodiment of the invention, the enzyme used in the processing method of the present invention is selected, for example, from the group consisting of Ultrazym®AFP-L (e.g. from Novo Nordisk Ferment Ltd), Rohament® PL, Rohapect® TPL or PTF (AB Enzymes), Novozyme® 33095, Pectinex® Ultra AFP, UF, Ultra Colour or Ultra Clear (Novozymes A/S), Neopectinase PL1® (Novozymes A/S), pectin lyase 1A (nzytech), Depol 793 (Biocatalyst), Rapidase® Fibre (DSM) and mixtures thereof.

In an embodiment, the mixture is treated with a cellulase, such as EC 3.2.1.4, EC 3.2.1.91, or EC 3.2.1.21, or EC 3.2.1.99, and mixtures thereof.

The activity of the various cellulases that can be used in the present invention is determined using these known standards. One cellulase unit (U) is defined as the amount of enzyme that causes the release of 1.25 micromoles of glucose equivalents per minute at pH 4.6 and 40°C. One cellulolytic unit (ACU) is determined based on the reduction in viscosity of a guar gum solution. In a preferred embodiment, the activity is from 400 to 3000 micromoles/min/g, such as from 500 to 2500 micromoles/min/g.

In an embodiment of the invention, the enzyme used in the processing method of the present invention is selected from the group consisting of, for example, cellulase 13L (Biocatalysts), cellulase CE-3, cellulase FG conc. (Enzyme Development Corporation), cellulose GMY (HBI Enzymes Inc.) and mixtures thereof.

In an embodiment, the enzymatic treatment can be carried out using at least two carbohydrases, optionally at least three carbohydrases, optionally at least four carbohydrases, optionally less than 20 carbohydrases or less than 10 carbohydrases.

In an embodiment, a mixture of enzymes with an activity of more than 60 FBGU, optionally more than 75 FBGU is used. Optionally, the activity is less than 180 FBGU, optionally less than 150 FBGU and optionally less than 125 FBGU. For example, from 60 FBGU to 180 FBGU. One unit of fungal beta-glucanase (FBGU) is the amount of enzyme that hydrolyzes fungal beta-glucan to reducing sugars corresponding to 1 μmol/L glucose per minute at pH 5.0 and 30°C.

In an embodiment, cocoa pulp or pulp extract is treated with Viscozyme L (Novozymes A/S), which is a multi-enzyme complex containing a broad spectrum of carbohydrases, including arabanase, cellulase, beta-glucanase, hemicellulase and xylanase. It is within the scope of the present invention to use Viscozyme L to degrade the hemicellulose present.

Other enzymes that can be used in the context of the present invention include amylases (e.g. amyloglucosidases or glucoamylases or alpha-amylases, e.g. novozyme 26210, AD11MP amylases and AMG 1100 BG), proteases (Biobake WH20 or WCH20 (also includes xylanase) and Neurase 1.5 MG).

In a highly preferred embodiment of the present invention, the enzyme mixture comprises at least one cellulase, at least one pectinase and at least one amylase.

In a highly preferred embodiment, the enzyme mixture comprises cellulase, pectinase, alpha-amylase and amyloglucosidase.

In an embodiment, the total amount of enzyme mixture used is from 0.10 to 20% by weight of the substrate (preferably the paste defined above), preferably from 0.20 to 10%, more preferably from 0.5 to 5.0%.

In a preferred embodiment, the amount of each individual enzyme is independently present in an amount of from 0.025 to 5.0% by weight of the substrates (preferably those mentioned above), preferably from 0.05 to 2.5%, more preferably from 0.1 to 1.25%.

Accordingly, in a highly preferred embodiment, the present invention utilizes an enzyme mixture that comprises at least one cellulase, at least one pectinase, and at least one amylase, wherein the total amount of the enzyme mixture utilized is from 0.10 to 20% by weight of the substrate, and the amount of each individual enzyme is independently present in an amount from 0.025 to 5.0% by weight of the substrate.

In an embodiment of the present invention, a dried mass, preferably an alternative to traditional cocoa mass/liquor, with an increased sugar content is provided. The sugar is preferably obtained from pulp, pulp extract, pulp-free and seed-free portion and/or by seed/seed portion degradation (e.g. degradation of starch and/or cellulose using enzymes in the seed).

In an embodiment, the sugar is a monosaccharide (e.g. fructose, fucose, galactose, glucose and/or rhamnose), a disaccharide (e.g. lactose, maltose and/or sucrose) and/or an oligosaccharide (e.g. less than 20, less than 10 or less than 8 saccharide units) and is referred to herein as "cocoa sugar". Preferred sugars present in the compositions of the present invention include sucrose, glucose or fructose, as well as mixtures thereof. In a preferred embodiment, the sugar mixture of the present invention comprises at least 75 wt.%, based on the weight of the sugar mixture, of a combination of glucose and fructose, preferably at least 80 wt.% or at least 85 wt.% or at least 90 wt.%. In a preferred embodiment, the sugar mixture of the present invention contains less than 100% by weight, based on the weight of the sugar mixture, of a combination of glucose and fructose, preferably less than 99.5% by weight or less than 99% by weight or less than 95% by weight. Preferably, from 75% by weight to 100% by weight or from 85% by weight to 99% by weight.

In an embodiment, the sugar of the cocoa pulp extract is sugars selected from the group consisting of glucose, sucrose, fructose and combinations thereof, and is defined herein as "cocoa sugar". The content and nature of the cocoa sugar may vary depending on the variety of cocoa pods.

In a preferred embodiment, the above sugar content is determined by the HPAEC-PAD (high performance anion exchange chromatography with pulsed amperometric detection) method. The preferred method of analysis is described in the examples section.

In a preferred embodiment, the use of pulp and/or pulp extract provides insoluble and soluble dietary fiber to the mixture, as well as sugars and other solids. The insoluble dietary fiber is cellulose, hemicellulose, or a combination thereof. In a preferred embodiment, the soluble dietary fiber is pectin.

The percentage of fiber depends on the moisture content of the pulp and pulp extract.

In an embodiment, the pulp and pulp extract comprise dietary fiber (preferably pectin, hemicellulose and cellulose) by weight from 0.75 to 50.0%, from 1.0 to 40% or from 1.25 to 30% by weight. For example, from 0.75 to 7.5% by weight (e.g. high moisture content, pulp) or from 8.0 to 50.0% by weight (e.g. lower moisture content, dried pulp or pulp extract). Reducing the amount of polysaccharides, preferably enzymatically, results in a decrease in the amount of these fibers in the mixture.

In a preferred embodiment, the seeds and/or a portion of the seeds provide starch and cellulose, as well as other components. In an embodiment, the seeds and/or a portion of the seeds contain from 2.5 to 30.0 wt.% starch and cellulose, from 5.0 to 25.0 wt.% and from 10.0 to 20.0 wt.%. Reducing the amount of polysaccharides, preferably enzymatically, results in a reduction in the amount of these components in the mixture.

In a preferred embodiment, the seeds and/or part of the seeds provide sugar, preferably mono- and disaccharides as defined above, for the mixture, as well as other components. In an embodiment, the seeds and/or part of the seeds contain from 0.25 to 10.0 wt.% of such total sugar, from 0.5 to 5.0 wt.% and from 0.75 to 3.0 wt.%. Reducing the amount of polysaccharides, preferably enzymatically, results in an increase in the amount of these components in the mixture.

In a preferred embodiment, the average degree of polymerization of the dietary fiber, preferably both insoluble and soluble together, is greater than 12, preferably greater than 20, preferably greater than 30 and preferably greater than 40. In an embodiment, the average degree of polymerization of the dietary fiber is less than 100, preferably less than 75. For example, from 40 to 75. In an embodiment, the average degree of polymerization is determined using the SEC-MALS (size exclusion chromatography with multi-angle light scattering) method, for example, the sample was partially dissolved in DMSO.

As indicated below, the reduction in the amount of polysaccharides by the processing of the present invention is accomplished by breaking down larger polysaccharides into smaller polysaccharides, oligosaccharides (preferably 3-8 saccharides or 3-10 saccharides) and/or di-/monosaccharides.

In an embodiment, the total dietary fiber content and its fractions in the mixture are measured by the enzymatic gravimetric method, the rapid integrated method for determining total dietary fiber, as described in the Journal of AOAC International, Volume 102, Number 1, January-February 2019, pp. 196–207(12).

In an embodiment of the present invention, the cocoa pulp extract is prepared by a process that comprises extracting cocoa pulp from a cocoa pod, heat treating, optionally concentrating and drying the cocoa pulp.

In an embodiment, the cocoa pulp is extracted from the cocoa pod, for example according to the method of EP 0442421 (Nestle SA). An alternative method for extracting the cocoa pulp from the cocoa pods in an embodiment of the present invention is to use a commercially available depulper, preferably equipped with brushes.

The seeds can be obtained by methods generally known in the art. The seeds may retain some pulp from the fruit or may be re-mixed with pulp and/or pulp extract, as appropriate. Likewise for the pulp-free and seed-free portion.

The components for use in preparing the mixture of the present invention are preferably pasteurized, preferably mixed together once, but may be processed separately.

In the embodiment described above, the thermal treatment step refers to treatment at high temperatures (typically 120°C to 160°C) for a very short period of time (typically no more than 200 seconds and optionally typically more than 50 seconds) to inactivate any microbial contaminants so that the ingredient is safe for human consumption. In an alternative embodiment, other temperatures, such as 60°C to 100°C, and other times, such as 10 to 120 seconds, may be used. The thermal treatment step is not particularly limited, provided that pasteurization occurs without degradation of the product.

Although it is preferable to process the cocoa pulp in a fresh state, in an embodiment, after extraction, the cocoa pulp may be frozen prior to further processing to ensure freshness. Such freezing may be carried out using standard equipment for freezing vegetable and fruit material known in the art. When freezing is used at any stage of the process of the present invention, the pulp or pulp extract is preferably first defrosted before being incorporated into the product of the invention.

In an embodiment, the treatment for reducing the polysaccharide content and/or changing the viscosity can be carried out mechanically or physically, for example by centrifugation, preferably in a decanter centrifuge. Such treatment can be used to remove polysaccharides present in the pulp.

In an embodiment, the above ratios are based on a solids content of the pulp or pulp extract of from 10 to 75%, preferably for cocoa pulp with a total solids content of from 10 to 20%.

In an embodiment, the mixture is treated to increase the pH, for example, the mixture is treated with an alkaline salt or a base. The nature of such a compound is not particularly limited, but preferably the compound is food grade. In a preferred embodiment, the cocoa pulp is treated with a compound such as mono-/di-/tri-sodium-/potassium-/calcium phosphates, mono-/di-ammonium phosphate, sodium hydroxide, calcium hydroxide, potassium hydroxide, sodium carbonate, calcium carbonate or potassium carbonate and mixtures thereof, to increase the pH.

In an embodiment, the alkali salt or base is mixed with the mixture in an amount of more than 0.10 wt.% of the cocoa pulp or cocoa pulp extract, preferably more than 0.15 wt.%, preferably more than 0.20 wt.%. In an embodiment, the alkali salt or base is combined with the cocoa or cocoa pulp extract in an amount of less than 1.25 wt.% of the cocoa pulp or cocoa pulp extract, preferably less than 1.0 wt.%, preferably less than 0.90 wt.%, such as from 0.10 wt.% to 1.25 wt.%, from 0.20 wt.% to 0.90 wt.% or from 0.25 wt.% to 0.85 wt.%.

In an embodiment, as mentioned above, the pH of the cocoa pulp is increased to a value exceeding the range of 2.75-4.0, optionally exceeding 3.3-4.0 or 3.0-3.7 (all measurements at 20°C), for example the pH is increased to a value greater than 4.5, greater than 5.0, greater than 5.5 or greater than 6.0. For example, the pH is increased, but to a value of not greater than 8.0, not greater than 7.5, or not greater than 7.0, or not greater than 6.5, or not greater than 6.0.

In a preferred embodiment, the pH increasing agent is added to the mixture as an aqueous solution or suspension. In a preferred embodiment, the concentration of the agent in water is from 5 g/100 ml to 100 g/100 ml or from 5 g/100 ml to 50 g/100 ml, preferably from 10 g/100 ml to 30 g/100 ml. Preferably, when adding the agent as an aqueous solution or suspension, undesirable gelation does not occur, which can increase the viscosity of the pulp when higher concentrations of the agent are added.

In an embodiment, the enzymatic treatment is performed after the pH increasing treatment. In an alternative embodiment, the enzymatic treatment is performed before the pH correcting treatment.

In an embodiment, the enzymatic treatment is carried out when the pH of the pulp is from 3.3 to 6.0, preferably from 4.25 to 5.0.

In an alternative embodiment, the pH correction treatment is carried out using dialysis (ion exchange). For example, using the processes described in publication EP 0049497 (Nestle SA).

The present invention provides advantageous properties in terms of reducing or eliminating added sugar, with sweetness provided by a natural source that also contains other components of the cocoa pod that contribute to the flavor properties of chocolate.

With regard to added sugar, in an embodiment the term "added sugar" refers to refined sugar, and includes processed sugars, such as white or brown sugars, which have standard definitions of nutrients. As specified in Regulation (EC) No 1924/2006, the present invention preferably relates to chocolate products to which sugars are not added, and the product does not contain any added mono- or disaccharides or any other food products used for their sweetening properties and other than the sugars naturally present in the ingredients.

Accordingly, the present invention provides an alternative to adding sugars by providing natural sugars that are present in the source - cocoa mass, cocoa butter and/or cocoa powder. Thus, the present invention provides a sugar chocolate product without added sugar, containing natural sugar.

Fermentation

The fermentation step of the present invention can be carried out using appropriate methods.

In an embodiment, the fermentation is selected from the group consisting of natural fermentation, controlled fermentation or controlled submersion fermentation, as well as a combination of these processes.

In an embodiment, the pods of plants of the genus theobroma are unfermented, slightly fermented or fermented. In an embodiment, the above terms can be defined as follows.

In an embodiment, the fermentation duration is up to 10 days, for example from 2 to 8 days. Fermentation is usually carried out for 2 to 6 days, depending on the variety, origin and desired taste and aroma.

No fermentation means no intentional fermentation, and low fermentation means less than 2 days of fermentation.

Fermentation is preferably carried out on the paste obtained in the present invention.

In an embodiment, the fermentation is a natural fermentation and is carried out using yeast, acetic acid and/or lactic acid bacteria from the local environment (e.g. present in the paste, in the ambient air, etc.). In an embodiment, the temperature profile of the fermentation remains uncontrolled and depends on the stage of fermentation. In an embodiment, the fermentation paste is distributed and turned/stirred at regular intervals to ensure complete fermentation.

In an embodiment, the fermentation is a controlled fermentation, open. Fermentation is preferably controlled by adding specially selected strains of yeast, acetic acid and/or lactic acid bacteria. The choice of additive can be determined depending on the fermentation stage and can be used in combination with the initial stages of natural fermentation. In an embodiment, the temperature profile of the fermentation is controlled for optimal growth conditions for the selected microorganism. In an embodiment, acidity regulators can be added to improve the fermentation efficiency of each stage in accordance with the selected microorganism. In an embodiment, the fermentation paste is distributed and turned/mixed at regular intervals to ensure complete fermentation. Alternatively, a fixed bed reactor can be used.

In an embodiment, the fermentation is a controlled submerged fermentation. In an embodiment, the mixture is fermented inside a closed bioreactor (e.g., a stirred tank).

Fermentation is preferably controlled by adding specially selected strains of yeast, acetic acid and/or lactic acid bacteria. The choice of additive can be determined depending on the fermentation stage and can be used in combination with the initial stages of natural fermentation. In an embodiment, the temperature profile of the fermentation is controlled for optimal growth conditions for the selected microorganism. In an embodiment, acidity regulators can be added to improve the efficiency of fermentation of each stage in accordance with the selected microorganism.

In this embodiment, the fermentation duration is up to 10 days, but preferably up to 96 hours or up to 72 hours or up to 48 hours. In an embodiment, during the fermentation, the fermentation paste is continuously stirred. In an embodiment, during the aerobic phase, fermentation oxygen or compressed air is preferably added to the fermentation mixture.

Fermentation can be carried out at standard temperatures, such as 20 to 75°C, 24 to 72°C, or 20 to 55°C. Fermentation can be controlled to ensure an anaerobic or aerobic process if necessary.

In an embodiment, starter cultures known in the art can be used to initiate fermentation.

In an alternative embodiment, the seeds and/or a portion of the seeds are fermented before being combined with the other components of the invention. The mixture may then undergo further fermentation or no further fermentation may be required.

In an alternative embodiment, the chocolate products of the invention are unroasted. "Unroasted" means that the composition is prepared without roasting, and the cocoa solids (such as, for example, cocoa beans or nibs, etc.) are not subjected to high temperatures (e.g., 140°C or higher or 120°C or higher) for a long time (e.g., 30 minutes or more). Without being limited by any mechanism, it is believed that a non-roasted process at or under conditions of an insufficiently high temperature (preferably less than 120°C, more preferably less than or equal to 110°C, even more preferably less than or equal to 100°C, most preferably less than or equal to 90°C, such as less than or equal to 80°C) and/or for a sufficiently short duration (preferably less than 30 minutes, more preferably less than 20 minutes, even more preferably less than 10 minutes, most preferably less than 5 minutes, such as less than 4 minutes) prevents a significant degree of undesirable chemical reactions, such as the Maillard reaction, from occurring and, therefore, does not produce a significant amount of aroma-active substances that could contribute strong roasted notes to the composition. The roasting process or step should be distinguished from a process such as flash heating, whereby raw ingredients such as cocoa beans and/or nibs may be treated at high temperatures (typically 120 to 160°C) for a very short period of time (typically no more than 200 seconds) to inactivate any microbial contaminants to ensure the ingredient is safe for human consumption. Such antimicrobial and/or antibacterial treatment processes and/or steps are also considered to be part of the non-roasting process.

Production of cocoa liquor/mass

The present invention provides new compositions that are an alternative to traditional cocoa and cocoa liquor-based masses.

Accordingly, the present invention may provide an alternative to traditional cocoa mass/cocoa powder, in which the seeds or part of the seeds have been fermented or not.

Similarly, the seeds and/or a portion of the seeds are not roasted or roasted before combining with the other components of the invention. The mixture can then be roasted or further roasted in a drying step to produce the dried mass of the present invention.

Thus, the process of the present invention provides the following embodiments.

The process includes:

● combining pulp with seeds and/or part of the seeds to form a mixture,

● grinding the mixture to reduce the particle size and form a paste, and

● drying and optionally frying the paste to form a dried mass.

The process includes:

● combining pulp with seeds and/or part of the seeds to form a mixture,

● grinding the mixture to reduce the particle size and form a paste,

● fermentation of paste,

● drying and optionally frying the paste to form a dried mass.

In a preferred embodiment, the mixture also comprises a non-pulp and non-seed part of the fruit, such as the stalk, placenta, endocarp, mesocarp and/or endocarp, particularly preferably the placenta.

In a preferred embodiment, the dried mass has a sugar content, preferably a mono- and disaccharide content, of more than 8.0 wt.%, preferably more than 10.0 wt.%, preferably more than 12.0 wt.% and preferably more than 14.0 wt.%. In a preferred embodiment, the sugar content, preferably mono- and disaccharides, is less than 35.0 wt.%, preferably less than 30.0 wt.%, preferably less than 27.5 wt.% and preferably less than 25.0 wt.%. Preferably, from 8.0 wt.% to 35.0 wt.% or from 12.0 wt.% to 25.0 wt.%. The percentages refer to the actual mass, i.e. together with the moisture present.

In a preferred embodiment, the dried mass has a total dietary fiber content, i.e. insoluble and soluble, of more than 2.0 wt.%, preferably more than 3.0 wt.%, preferably more than 4.0 wt.% and preferably more than 5.0 wt.%. In a preferred embodiment, the paste has a total dietary fiber content, i.e. insoluble and soluble, of less than 18.0 wt.%, preferably less than 16.0 wt.%, preferably less than 14.0 wt.% and preferably less than 13.5 wt.%. Preferably from 2.0 wt.% to 18.0 wt.% or from 4.0 wt.% to 14.0 wt.%. The percentages refer to the actual weight, i.e. together with the moisture present.

In a preferred embodiment, the fat content of the dried mass is more than 18.0 wt.%, preferably more than 20.0 wt.%, preferably more than 22.0 wt.% and preferably more than 25.0 wt.%. In a preferred embodiment, the total solids content of the milk substrate is less than 50.0 wt.%, preferably less than 45.0 wt.%, preferably less than 40.0 wt.% and preferably less than 35.0 wt.%. Preferably, from 18.0 wt.% to 50.0 wt.% or from 2.0 wt.% to 40.0 wt.%. The percentages refer to the actual mass, i.e. together with the moisture present.

Accordingly, in a highly preferred embodiment, the present invention provides a dried mass that comprises:

● sugar, preferably mono- and disaccharides, in an amount from 8.0 wt.% to 35.0 wt.%,

● fat in an amount from 18.0 wt.% to 50.0 wt.% and

● moisture in an amount from 0.1 mass% to 10.0 mass%.

In a further highly preferred embodiment, the present invention provides a dried mass that comprises:

● sugar, preferably mono- and disaccharides, in an amount from 12.0 wt.% to 25.0 wt.%,

● fat in an amount from 18.0 wt.% to 50.0 wt.% and

● moisture in an amount from 0.1 mass% to 5.0 mass%.

Accordingly, in a highly preferred embodiment, the present invention provides a dried mass that comprises:

● sugar, preferably mono- and disaccharides, in an amount from 8.0 wt.% to 35.0 wt.%,

● total amount of dietary fiber from 2.0 wt.% to 18.0 wt.% and

● moisture in an amount from 0.1 mass% to 10.0 mass%.

In a further highly preferred embodiment, the present invention provides a dried mass that comprises:

● sugar, preferably mono- and disaccharides, in an amount from 12.0 wt.% to 25.0 wt.%,

● total amount of dietary fiber from 4.0 wt.% to 14.0 wt.% and

● moisture in an amount from 0.1 mass% to 5.0 mass%.

Accordingly, in a highly preferred embodiment, the present invention provides a dried mass that comprises:

● sugar, preferably mono- and disaccharides, in an amount from 8.0 wt.% to 35.0 wt.%,

● total amount of dietary fiber from 2.0 wt.% to 18.0 wt.%,

● fat in an amount from 18.0 wt.% to 50.0 wt.% and

● moisture in an amount from 0.1 mass% to 10.0 mass%.

In a further highly preferred embodiment, the present invention provides a dried mass that comprises:

● sugar, preferably mono- and disaccharides, in an amount from 12.0 wt.% to 25.0 wt.%,

● total amount of dietary fiber from 4.0 wt.% to 14.0 wt.%,

● fat in an amount from 18.0 wt.% to 50.0 wt.% and

● moisture in an amount from 0.1 mass% to 5.0 mass%.

In a preferred embodiment, the protein content is more than 5.0 wt.%, preferably more than 7.5 wt.%, preferably more than 9.0 wt.% and preferably more than 10.0 wt.%. In a preferred embodiment, the protein content of the dried mass is less than 22.0 wt.%, preferably less than 20.0 wt.%, preferably less than 17.5 wt.% and preferably less than 15.0 wt.%. Preferably from 5.0 wt.% to 22.0 wt.% or from 9.0 wt.% to 17.5 wt.%. The percentages refer to the actual mass, i.e. together with the moisture present.

In an embodiment, drying is preferably performed using spray drying, vacuum drying, drum drying, oven drying, foam drying, tray drying, fluidized bed drying, crystallization drying (preferably using a seed sugar crystal), roller drying or freeze drying (lyophilization).

In an embodiment, the drying occurs at more than 45°C, preferably more than 50°C, preferably more than 55°C and more than 60°C. In an embodiment, the drying occurs at a temperature of less than 125°C, preferably less than 100°C, preferably less than 90°C and preferably less than 85°C or less than 80°C. In a preferred embodiment, the drying occurs in the range from 45°C to 100°C and more preferably from 45°C to 85°C.

In an embodiment, the drying is carried out for more than 1 hour, preferably more than 5 hours, preferably more than 10 hours, more than 15 hours or more than 20 hours. In an embodiment, the drying is carried out for less than 100 hours, preferably less than 72 hours, preferably less than 60 hours, preferably less than 50 hours or less than 40 hours.

In a preferred embodiment, drying occurs in the range of 45°C to 125°C and from 1 hour to 72 hours. The above ranges apply to drying in an oven, optionally with or without vacuum.

In an embodiment of the present invention, the dried mass contains less than 10.0 wt.% water, preferably less than 8.0 wt.%, more preferably less than 5.0 wt.%, more preferably less than 3.0 wt.% and more preferably less than 2.0 wt.%. In an embodiment, it is noted that complete dehydration is potentially not achievable, so the water content is optionally greater than 0.1%, greater than 0.5% or greater than 1.0%. In a preferred embodiment, the above water content can be measured using a Karl Fischer analysis as described above or a halogen moisture analyzer (e.g. a Mettler-Toledo balance).

In an embodiment, an additional roasting step may be present, preferably where the mixture of the present invention is fermented and/or enzyme treated.

In an embodiment, the roasting occurs at a temperature of more than 85°C, preferably more than 100°C, preferably more than 105°C, preferably more than 125°C and more than 150°C. In an embodiment, the drying occurs at a temperature of less than 225°C, preferably less than 210°C, preferably less than 200°C and preferably less than 195°C or less than 180°C. In a preferred embodiment, the roasting occurs in the range of 85°C to 225°C, more preferably from 125°C to 200°C or from 100°C to 150°C.

In an embodiment, the roasting takes place for more than 10 minutes, preferably more than 20 minutes, or preferably more than 30 minutes. In an embodiment, the roasting takes place for less than 2 hours, preferably less than 1.5 hours, preferably less than 1 hour.

In a preferred embodiment, roasting occurs in the range of 85°C to 225°C and for 10 minutes to 2 hours.

Accordingly, in a highly preferred embodiment, the present invention provides a dried mass that is combined with other ingredients in chocolate products (e.g., sugar, cocoa butter, and/or milk-based ingredients) to produce an alternative chocolate product to those currently known. The dried mass of the present invention is an alternative to the conventionally used cocoa mass/cocoa liquor.

Alternative implementation options

The technology of the present invention can also be used to extract additional sugars from other materials of the genus Theobroma. Thus, the embodiments described above can be used in these embodiments below.

The present invention provides a processing method in which the processing steps can be carried out on a Theobroma-based substrate, preferably on a cocoa-based substrate, most preferably cocoa powder and/or cocoa mass/liquor (and corresponding materials obtained from other plants in the Theobroma genus).

Accordingly, the present invention provides a method comprising hydrolyzing cocoa powder and/or cocoa liquor.

In a preferred embodiment, the hydrolysing treatment comprises exposing cocoa powder and/or cocoa liquor to an enzyme.

In a preferred embodiment, the enzyme comprises an enzyme selected from the group consisting of pectinases, cellulases, xylanases, proteases and amylases and combinations thereof.

In a preferred embodiment, the enzyme is selected from amylases, preferably amyloglucosidase or glucoamylase or alpha-amylase.

In a preferred embodiment, when alpha-amylase is used, it is used in combination with amyloglucosidase.

In a preferred embodiment, the enzyme or enzyme mixture is used in an amount of 0.10 to 20% by weight of the substrate, preferably 0.20 to 10%, more preferably 0.5 to 5.0%.

In a preferred embodiment, the amount of amylases used is from 0.10 to 10% by weight of the substrate, preferably from 0.15 to 5.0%, more preferably from 0.20 to 2.5%.

In an embodiment, the enzyme treatment method is carried out for 10 minutes to 20 hours, 10 minutes to 10 hours, 10 minutes to 8 hours, 10 minutes to 6 hours, 15 minutes to 4 hours, 15 minutes to 2 hours, or 30 minutes to 2 hours.

In an embodiment, the mixture is subjected to enzymatic treatment at a temperature of from 10°C to 80°C, for example, the temperature during enzymatic treatment is from 20°C to 75°C, for example from 30°C to 65°C, from 55°C to 75°C or from 30°C to 55°C.

In an embodiment, the above-described processing methods can be performed together or separately with those described for pulp and pulp extracts.

In an embodiment, the substrate may be combined with pulp and/or pulp extract, preferably a cocoa-based substrate and cocoa pulp, preferably cocoa powder and/or cocoa mass/and cocoa pulp.

In one embodiment, the substrate and the pulp and/or pulp extract are combined to form a mixture comprising from 40 wt.% to 95 wt.% of the mixture, preferably from 50 wt.% to 90 wt.% and more preferably from 65 wt.% to 90 wt.% of the pulp and/or pulp extract and from 5 wt.% to 60 wt.% of the mixture, preferably from 10 wt.% to 50 wt.% and from 10 wt.% to 35 wt.% of the substrate.

In a preferred embodiment, the mixture contains from 40 wt.% to 95 wt.% pulp and from 5 wt.% to 60 wt.% cocoa powder and/or cocoa liquor.

In a preferred embodiment, the mixture comprises from 50 wt.% to 80 wt.% pulp and from 20 wt.% to 50 wt.% cocoa solution.

In a preferred embodiment, the mixture contains from 70% by weight to 90% by weight pulp and from 10% by weight to 30% by weight cocoa powder.

In a highly preferred embodiment of the present invention, the enzyme mixture comprises at least one cellulase, at least one pectinase and at least one amylase.

In a highly preferred embodiment, the enzyme mixture comprises cellulase, pectinase, alpha-amylase and amyloglucosidase.

In an embodiment, the total amount of enzyme mixture used is from 0.10 to 20% of the total weight of the substrate and cocoa pulp, preferably from 0.20 to 10%, more preferably from 0.5 to 5.0%.

In a preferred embodiment, the amount of each individual enzyme is independently present in an amount of from 0.025 to 5.0% by weight of the combined weight of the substrate and cocoa pulp, preferably from 0.05 to 2.5%, more preferably from 0.075 to 1.25%, and more preferably from 0.1 to 0.75%.

In a highly preferred embodiment, the amount of each individual pectinase and cellulase is independently present in an amount of from 0.025 to 5.0% by weight of the cocoa pulp (wet weight), preferably from 0.05 to 2.5%, more preferably from 0.1 to 1.75%, and more preferably from 0.25 to 1.25%.

In a highly preferred embodiment, each individual amylase is independently present in an amount of from 0.25 to 5.0% by weight of the substrate (preferably cocoa pulp and/or cocoa liquor), preferably from 0.40 to 2.5%, more preferably from 0.50 to 1.75%, and more preferably from 0.50 to 1.50%.

Accordingly, in a highly preferred embodiment, the present invention utilizes an enzyme mixture that comprises at least one cellulase, at least one pectinase, and at least one amylase, wherein the total amount of the enzyme mixture utilized is from 0.10% to 20% of the combined weight of the substrate and cocoa pulp, wherein each individual enzyme is independently present in an amount of from 0.025 to 5.0% of the combined weight of the substrate and cocoa pulp.

Thus, the present invention provides a method comprising:

● enzymatic treatment of a mixture of cocoa pulp and cocoa powder and/or cocoa mass,

● wherein the enzymatic treatment uses a mixture of enzymes that contains at least one cellulase, at least one pectinase and at least one amylase, wherein the total amount of the enzyme mixture used is from 0.10 to 20% of the total weight of the cocoa pulp and cocoa powder and/or cocoa liquor, and each individual enzyme is independently present in an amount of from 0.025 to 5.0% of the total weight of the cocoa pulp and cocoa powder and/or cocoa liquor.

In a highly preferred embodiment, the present invention provides a method comprising:

enzymatic treatment of a mixture of cocoa pulp and cocoa powder and/or cocoa liquor, wherein a mixture of enzymes is used for the enzymatic action, which contains cellulase in an amount of 0.1 to 1.50% of the mass of the cocoa pulp (wet mass), pectinase in an amount of 0.1 to 1.50% of the mass of the cocoa pulp (wet mass), alpha-amylase in an amount of 0.5 to 1.75% of the mass of the cocoa powder and/or cocoa liquor, and amyloglucosidase in an amount of 0.5 to 5.0% of the mass of the cocoa powder and/or cocoa liquor.

In a highly preferred embodiment, the enzymatic treatment conditions are from 30 minutes to 1.5 hours, preferably from 45 minutes to 75 minutes; at a temperature of from 55°C to 75°C; and at a pH of from 4.0 to 5.5, preferably from 4.25 to 4.75.

According to the present invention, a mixture is proposed comprising:

● from 40 wt.% to 95 wt.% pulp and/or pulp extract, preferably wherein the pulp and/or pulp extract has been processed to reduce the polysaccharide content,

● from 5 wt.% to 60 wt.% cocoa mass/cocoa liquor and/or cocoa powder, preferably wherein the cocoa mass/cocoa liquor and/or cocoa powder has been treated to reduce the polysaccharide content.

In a preferred embodiment, the mixture is treated with a combination of enzymes comprising cellulase, pectinase and amylase. The above-described method preferably increases the sugar content of the treated material, which may change the required amount of sugars from the pulp and from the pulp extract, and may also compensate for any loss of sugar in the pulp and pulp extracts during further processing, such as drying, enzyme deactivation, etc.

In an embodiment of the present invention, the cocoa pulp extract comprises cellulose or hemicellulose, and a combination thereof. In an embodiment, as described below, the cocoa pulp is processed to preferably partially or substantially completely remove the cellulose or hemicellulose, or a combination thereof, and optionally preferably partially remove other polysaccharides.

In an embodiment, the mixture obtained above is dried. In an embodiment of the present invention, the dried mass contains less than 10.0 wt.% water, preferably less than 8.0 wt.%, more preferably less than 5.0 wt.%, more preferably less than 2.0 wt.% and more preferably less than 1.0 wt.%. In an embodiment, it is noted that complete dehydration is potentially not achievable, so the water content is optionally greater than 0.1%, greater than 0.5% or greater than 1.0%. In a preferred embodiment, the water content above can be measured using a Karl Fischer analysis as indicated above or a halogen moisture analyzer (e.g., a Mettler-Toledo balance).

In an embodiment, drying is preferably performed using spray drying, vacuum drying, drum drying, oven drying, foam drying, tray drying, fluidized bed drying, crystallization drying (preferably using a seed sugar crystal), roller drying or freeze drying (lyophilization).

In an embodiment, the drying occurs at more than 45°C, preferably more than 50°C, preferably more than 55°C and more than 60°C. In an embodiment, the drying occurs at a temperature of less than 125°C, preferably less than 100°C, preferably less than 90°C and preferably less than 85°C or less than 80°C. In a preferred embodiment, the drying occurs in the range from 45°C to 100°C and more preferably from 45°C to 85°C.

In an embodiment, the drying is carried out for more than 1 hour, preferably more than 5 hours, preferably more than 10 hours, more than 15 hours or more than 20 hours. In an embodiment, the drying is carried out for less than 72 hours, preferably less than 60 hours, preferably less than 50 hours or less than 40 hours.

In a preferred embodiment, drying occurs in the range of 45°C to 125°C and from 1 hour to 72 hours. The above ranges apply to drying in an oven, optionally with or without vacuum.

The dried mixture may be further processed to produce a powder. The powder may be obtained from the dried mixture using standard milling methods, such as milling, ball milling, jet milling, 2-, 3- or 5-roll milling. In an embodiment, the powder may be further refined during the production of the chocolate product, such as during the conching process in the preparation of chocolate.

The enzyme treatment can result in an improvement in the taste sensation of chocolate products, preferably chocolate containing the composition of the present invention. The present invention also provides for flavor differentiation.

Chocolate product and chocolate-like products

General products of invention

The present invention provides novel chocolate products and chocolate-like products containing the materials of the present invention.

The term "chocolate-like" encompasses products in which components traditionally provided by the cocoa plant are replaced by similar materials obtained from other plants of the genus Theobroma, obtained by the process of the present invention.

The material of the present invention provides an alternative to the traditional cocoa mass/cocoa powder, and preferably also a portion of the added sugar, commonly used in chocolate production.

In an embodiment, the compositions of the invention may suitably be chocolate products (as defined herein) and more suitably they may be chocolate or a chocolate compound. Regardless of any other legal definitions that may be used, compositions of the invention containing cocoa cake in the range of 25% by weight to 35% by weight together with a milk ingredient (such as milk powder) may be informally referred to herein as "milk chocolate" (this term also covers other similar chocolate products with similar amounts of cocoa cake or substitutes). Regardless of any other legal definitions available for use, compositions of the invention containing cocoa cake in excess of 35% by weight (up to 100% (i.e. pure cocoa cake)) may be informally referred to herein as "dark chocolate" (this term also covers other similar chocolate products with similar amounts of cocoa cake or substitutes).

The term “chocolate” in the context of this document means any product (and/or component thereof, if it is to be considered a product) that meets the legal definition of chocolate in any jurisdiction and also includes a product (and/or component thereof) in which all or part of the cocoa butter (CB) has been replaced by cocoa butter equivalents (CBE) and/or cocoa butter replacers (CBR).

The term "chocolate compound product" in this document (unless the context clearly indicates otherwise) means chocolate-like analogues characterised by the presence of cocoa cake (which includes cocoa liquor/mass, cocoa butter and cocoa powder) in any quantity, although in some jurisdictions a compound product may be legally defined as containing a minimum quantity of cocoa cake.

The term "chocolate product" in the context of this document means chocolate, composite product and other related materials that contain cocoa butter (CB), cocoa butter equivalents (CBE), cocoa butter replacers (CBR) and/or cocoa butter substitutes (CBS). Thus, a chocolate product includes products based on chocolate and/or based on chocolate analogues and, therefore, it can be based on, for example, dark, milk or white chocolate.

Unless the context clearly indicates otherwise, it will also be understood that in the present invention any one chocolate product may be used as a substitute for any other chocolate product, and that neither the term "chocolate" nor the term "compound product" should be construed as limiting the scope of the invention to a particular type of chocolate product. A preferred chocolate product comprises chocolate and/or a compound product, a more preferred chocolate product comprises chocolate, a most preferred chocolate product comprises chocolate, as defined by law in a primary jurisdiction (such as Brazil, the European Union and/or the United States).

The term "chocolate-containing coating" in the context of this document (also referred to as "chocolate-containing shell") denotes coatings obtained from any chocolate product. The terms "chocolate coating" and "compound product coating" may be defined in a similar manner. Similarly, the terms "chocolate-containing composition (or mass)", "chocolate composition (or mass)" and "compound composition (or mass)" denote compositions (or masses) which, respectively, contain in whole or in part a chocolate product, chocolate and a compound product as their component(s). Depending on their constituent parts, the definitions of such compositions and/or masses may, of course, partially overlap.

The term "chocolate-containing confectionery" in the context of this document means any food product that contains a chocolate product and optionally also other ingredients and may therefore refer to food products such as sweets, wafers, cakes and/or biscuits in which the chocolate product comprises a chocolate coating and/or product mass. The chocolate-containing confectionery may contain the chocolate product in any suitable form, such as inclusions, layers, grains, pieces and/or drops. The confectionery may further contain any other suitable inclusions, such as crunchy inclusions, such as cereals (e.g. puffed and/or fried rice) and/or pieces of dried fruit.

The chocolate product of the invention can be used to form a tablet and/or a bar, to coat confectionery products and/or to prepare more complex confectionery products. Before using it to prepare chocolate-containing confectionery products, inclusions can optionally be added to the chocolate product according to a desired recipe. As will be apparent to a person skilled in the art, in some cases the product of the invention will have the same recipe and the same ingredients as the corresponding composition and/or mass, while in other cases, especially when inclusions are added or for more complex products, the final recipe of the product may differ from the recipe of the composition and/or mass used to prepare it.

In one highly preferred embodiment of the invention, the chocolate-containing confectionery product comprises a substantially solid moulded chocolate tablet, chocolate bar and/or baked product surrounded by substantial quantities of chocolate product. These products are, for example, prepared by substantially filling a mould with the chocolate product, optionally adding inclusions and/or baked product to such mould to force the chocolate product out of the mould (so-called wet coating methods), with further coating of the mould with chocolate product if necessary. For such highly preferred products of the invention, the chocolate product constitutes a substantial part of the product or the entire product and/or a thick outer layer surrounding an inner baked product (e.g. multi-layer wafers and/or cookies). Such solid products, where the mould is substantially filled with chocolate, are to be distinguished from products that comprise moulded thin chocolate shells, where a variety of problems arise. To produce a thin chocolate-coated shell, the mold is inverted to remove excess chocolate and/or stamped with a cold plunger to form the shell and essentially release the mold. This leaves the mold coated in a thin layer of chocolate, to which additional ingredients and fillings can be added to form the interior of the product.

Unless the context of this document clearly indicates otherwise, it will also be well understood by a person skilled in the art that the term "chocolate-containing confectionery" as used herein can easily be substituted for and is equivalent to the term "chocolate confectionery" as used in this application, and in practice these two terms are interchangeable when used herein at will. However, where there is a difference in the meaning of these terms in the context given herein, a chocolate confectionery and/or a composite confectionery are preferred embodiments of the chocolate-containing confectionery of the present invention, wherein a preferred embodiment is a chocolate confectionery.

A preferred chocolate-containing confectionery product may comprise one or more ingredients that are, for example, selected from the group consisting of chocolate product(s), compound product(s), chocolate coating(s) and/or compound coating(s). The products may include uncoated products, such as chocolate bar(s) and/or chocolate tablet(s) with or without inclusions, and/or products coated with a chocolate product, such as biscuits, cakes, wafers and/or other coated confectionery. In a more preferred or alternative embodiment, any of the above products may comprise one or more cocoa butter replacers (CBR), cocoa butter equivalents (CBE), cocoa butter substitutes (CBS) and/or any suitable mixture(s) thereof.

In the chocolate-containing confectionery product, cocoa butter (CB) can be replaced by fats from other sources. Such products may typically contain one or more fats selected from the group consisting of lauric fat(s) (e.g. cocoa butter substitute (CBS) obtained from palm kernels); non-lauric vegetable fat(s) (e.g. based on palm or other specialty fats); cocoa butter substitute(s) (CBR); cocoa butter equivalent(s) (CBE) and/or any suitable mixture(s) thereof. Some CBE, CBR and especially CBS may contain predominantly saturated fats and very low levels of unsaturated omega-three and omega-six fatty acids (with health benefits). Thus, in one embodiment, in the chocolate-containing confectionery product of the invention, such types of fat are less preferred than CB.

In one embodiment of the invention there is provided a multi-layer product, optionally comprising a plurality of layers of baked food product (preferably selected from one or more wafer and/or biscuit layers) and/or one or more layers of filling therebetween with at least one coating layer arranged around these layers of food product, wherein the coating comprises a chocolate product of the invention or obtainable in accordance with the invention.

A further embodiment of the invention provides a chocolate-containing confectionery product further coated with chocolate (or equivalents thereof, such as a compound product), such as a praline, a product with a chocolate shell, and/or a wafer with a chocolate coating, or a biscuit, any of which may or may not be multilayered. The chocolate coating may be applied or created by any suitable means, such as enrobing or moulding. The coating may comprise a chocolate product of the invention or obtainable in accordance with the invention.

Another embodiment of the invention provides a chocolate-containing confectionery product of the present invention and/or used in the present invention, which comprises a filling surrounded by an outer layer, for example a praline, a product with a chocolate shell.

In another preferred embodiment of the invention, the food product comprises a multilayer coated chocolate product comprising a plurality of layers of wafer, chocolate material, biscuit and/or baked food product with a filling therebetween, wherein at least one layer or coating is a chocolate product (e.g. chocolate) of the invention. The multilayer product most preferably comprises a chocolate-containing confectionery product (e.g. as described herein) selected from a biscuit, a biscuit, a wafer(s), a muffin(s), an extruded snack(s) and/or a praline. An example of such a product are superimposed layers of baked wafer and/or layers of biscuit with a filling(s) between them and a chocolate coating.

Baked food products used in the invention may be sweet or savory. Preferred baked food products may comprise baked cereal food products, the term including food products that contain cereals and/or legumes. More preferred are baked cereal food products, most preferred are baked wheat food products, such as wafer(s) and/or cookies. Wafers may be flat or molded (e.g. in the form of an ice cream cone or basket), and cookies may have many different shapes, although preferred wafer(s) and/or cookies have a flat shape to allow it (they) to be layered together with the confectionery filling of the invention (and optionally a fruit filling). More preferred wafers are non-savory wafers, such as sweet or neutral flavored.

A non-limiting list of these possible baked food products that may contain chocolate compositions containing the chocolate product of the present invention and/or used in the present invention are selected from: high fat biscuits, cakes, breads, pastries and/or pies; for example, from the group consisting of: ANZAC biscuits, biscotto, cereal bars, kourabies, Nuremberg gingerbread, Basel gingerbread, almond biscuits, bourbon biscuits, butter biscuits, diet biscuits, custard biscuits, extruded snacks, Florentini, Garibaldi gingerbread, koulourakia, kourabiedes, Linzer torte, muffins, Oreo biscuits, Nice biscuits, peanut butter biscuits, polvorone, picelle, pretzel, croissant, sponge cake, shortbread, fruit pie (e.g. apple pie, cherry pie), lemon tart, banana bread, carrot cake, pecan pie, apple strudel, baklava, Berlin doughnut, lemon puff and/or similar products.

The chocolate product of the invention or obtained in accordance with the invention may preferably be suitable for use as one or more coatings and/or fillings (in whole or in part as a component).

The coating and/or filler may comprise multiple phases, such as one or more solid and/or fluid phases, such as fatty and/or aqueous liquid phases and/or gaseous phases, such as emulsions, dispersions, creams and/or foams.

Thus, in a broad sense, a further aspect of the invention includes the chocolate product described herein.

A further further aspect of the invention as a whole comprises the use of a chocolate product of the invention or obtained in accordance with the invention as a chocolate-containing confectionery product and/or a filling and/or a coating for a food product of the invention as described herein.

Specific products of the invention

In an embodiment of the present invention, the presence of an alternative to cocoa mass makes it possible to obtain a chocolate product or a chocolate-like product that is different from previously known chocolate products.

The "mass" of the present invention is the dried product of the processes of the present invention.

In an embodiment, the chocolate product comprises from 0.5% by weight to 95% by weight based on the weight of the chocolate product of the present invention depending on the final product, preferably from 5% to 85%, such as from 45% to 80%, less than 5% or from 8% to 20% by weight based on the weight of the chocolate product.

In an embodiment of the present invention, the mass of the present invention is the main source of cocoa mass/liquor in a chocolate product, preferably chocolate, preferably such mass is more than 60% of the weight of the chocolate product, preferably more than 75%, more preferably more than 80%, more preferably more than 85%, more preferably more than 90%, more preferably more than 95% and more preferably 100%.

In an embodiment, the chocolate product comprises from 0% by weight to 35% by weight of cocoa butter based on the weight of the chocolate product, depending on the final product, preferably from 0 to 30%, such as from 6 to 20%, less than 5% or from 20 to 35% cocoa butter based on the weight of the chocolate product. In an embodiment, the addition of cocoa butter is independent of any amount present in the cocoa mass.

In an embodiment of the present invention, the chocolate product, preferably chocolate, comprises from 5% by weight to 65% by weight of the chocolate product, preferably chocolate, sugar, preferably from 10% to 65%, more preferably from 15% to 60%, more preferably from 20% to 60%, such as from 20% to 55%, 20% and 40%, from 34% to 58% or from 37% to 50%.

In an embodiment, the sugar may be sucrose. In an alternative embodiment, some or all of the sugar may be dried pulp or dried pulp extract provided by the methods described in WO 2019115731, WO 2019115735 and WO 2019149909.

In an embodiment of the present invention, the chocolate product is selected from the group consisting of milk chocolate and dark chocolate.

In an embodiment, the composition consists essentially of cocoa mass and cocoa pulp extract or consists essentially of cocoa mass and dried cocoa pulp.

In the present invention, the term “consists essentially of” means at least 95.0 wt.%, more preferably at least 97.5 wt.%, more preferably at least 98.0 wt.%, and more preferably at least 99.0 wt.%, preferably up to and including 100.0 wt.%.

In an embodiment, the present invention provides a chocolate comprising a mass of the present invention and a cocoa pulp extract.

Accordingly, the present invention provides a method comprising the steps of:

● mixing the dried mass of the present invention with at least one other ingredient present in chocolate products, preferably sugar,

● it is not necessary to refine the resulting combination,

● it is not necessary to add other ingredients present in the chocolate product, and

● no need to conch the combination.

In an embodiment, the composition further comprises at least one component selected from the group consisting of a flavoring agent, a milk-based component, an emulsifier, cocoa butter and additional sugar, preferably at least one component selected from the group consisting of a milk-based component, an emulsifier and cocoa butter.

In an embodiment, the composition further comprises at least one component selected from the group consisting of a milk-based component, an emulsifier and cocoa butter, preferably at least one component selected from the group consisting of a milk-based component, an emulsifier and cocoa butter.

In an embodiment, when using cocoa butter in addition to the mass of the invention, the additional cocoa butter is used in an amount of less than 25% by weight of the chocolate product composition, preferably less than 20% by weight and preferably more than 2.5% by weight, preferably more than 5.0% by weight, for example from 2.5 to 25%.

In an embodiment of the present invention, the milk-based component is selected from the group consisting of non-fat milk solids, dry milk (optionally full fat, skimmed or semi-skimmed) and milk fat. In an embodiment, the dairy products may be spray dried under standard manufacturing parameters for these known products.

In an embodiment, the emulsifier is selected from the group consisting of lecithin, polyglycerol polyricinoleate and ammonium phosphatide. In an embodiment, the amount of emulsifier may be from 0.05 wt.% to 1.0 wt.% of the composition, preferably from 0.1 to 0.5%. In an alternative embodiment, the emulsifier may be absent.

In an embodiment, the flavoring agent may be any flavoring agent commonly used in the production of chocolate, such as vanilla/extract based (e.g. vanillin) or hazelnut/extract based (e.g. hazelnut paste or oil).

In an embodiment, the composition comprises inclusions. The inclusions may be any inclusions commonly used in the art, such as fruit-based inclusions, nut-based inclusions, cereal-based inclusions, and yoghurt-based inclusions. The inclusions may be in any commonly used form, such as crumbs, flakes, etc. The inclusions may be present in an amount of 2.5 to 25% of the weight of the chocolate product.

Specific, non-limiting chocolate formulations are described herein. In all embodiments below, the percentages are wt.% of the total weight of the chocolate product.

In an embodiment, the chocolate product composition comprises:

45-80% of the weight of the present invention

10–55% sugar source

0-15% cocoa butter

0.0–0.5% lecithin

In an embodiment, the chocolate product composition comprises:

8-25% by weight of the present invention

25–58% source of sugar,

10–25% cocoa butter

0.0–6.5% milk fat

15–40% dry milk

0.0–0.5% lecithin

Thus, the present invention can provide a chocolate product from a single source, i.e. cocoa pods, or a chocolate product that uses the compositions of the present invention and other traditional ingredients.

In an embodiment of the present invention, a method for producing a chocolate product is provided, in which all ingredients are obtained from a cocoa pod, i.e. the chocolate product consists essentially of ingredients obtained from a cocoa pod.

In an embodiment of the present invention, during the production of a chocolate product, dried cocoa pulp or cocoa pulp extract is mixed with other ingredients at the point at which added sugar is normally added.

In an embodiment of the present invention, a method for preparing a chocolate product is provided, comprising the steps of mixing the cocoa mass of the present invention and cocoa pulp or cocoa pulp extract. In an embodiment, combining with cocoa pulp or cocoa pulp extract can be carried out by any device conventionally used for mixing sugar with cocoa mass in conventional chocolate production.

In an embodiment, the chocolate composition of the present invention may optionally be refined using known equipment. In a preferred embodiment, the chocolate is refined to provide a non-grainy texture. For example, refining may be carried out to obtain a particle size (D90 as measured by a Malvern Mastersizer 3000) of less than 50 μm, preferably from 15 μm to 35 μm.

In one embodiment, the traditional conching method is used to prepare chocolate.

In an embodiment, the temperature in the conching step does not exceed 80°C, preferably does not exceed 75.5°C and preferably does not exceed 70°C. In a preferred embodiment, the temperature is greater than 35°C, greater than 40°C, preferably greater than 45°C, or greater than 50°C, or greater than 55°C.

In an embodiment, the conching is carried out for more than 5 hours, preferably 10 hours or preferably 15 hours or more. In an embodiment, the conching is carried out for a period of time less than 60 hours, preferably less than 50 hours.

In an embodiment, conching is carried out for a period of 5 hours to 60 hours at a temperature of 40°C to 80°C.

When the sugar source in the product is obtained from pulp and/or pulp extract, the temperature and duration of conching are preferably adjusted to meet the parameters given below.

In a preferred embodiment, the temperature at the conching stage does not exceed 60°C, preferably does not exceed 57.5°C and preferably does not exceed 56°C. Temperature control at this stage will prevent caramelization of the pulp and graininess of the texture of the final product. In a preferred embodiment, the temperature is more than 30°C, preferably more than 35°C, or more than 40°C, or more than 45°C.

In an embodiment, the conching is carried out for more than 1.5 hours, preferably 2 hours or more, preferably 2.5 hours or more. In an embodiment, the conching is carried out for a period of time less than 8 hours, preferably less than 6 hours.

In an embodiment, conching is carried out for a period of 1.5 hours to 8 hours at a temperature of 30°C to 60°C.

In an embodiment, the conching speed is from 200 rpm to 2000 rpm, preferably from 400 rpm to 1600 rpm.

In a preferred embodiment, the pulp and/or pulp extract is not caramelized, for example, the process steps used to obtain the composition of the invention do not result in caramelization.

In an embodiment, the conching speed and/or temperature may vary during the conching stage within the ranges specified above.

All technical and scientific terms used herein, unless otherwise defined, have and shall have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs.

Unless otherwise expressly stated in the text, the plural forms of terms in this document shall be understood as including the singular form, and vice versa.

In all the ranges specified above, the end points of the ranges are included in the range area as they were written. In addition, it is possible to combine the end points of the widest ranges in the embodiment and the end points of narrower ranges.

It should be understood that the sum of any amounts expressed herein as percentages may not (subject to rounding errors) exceed 100%. For example, the sum of all components that are included in a composition of the invention (or part(s) thereof) may, in weight (or other) percentages of the composition (or similar part(s) thereof), add up to 100%, subject to rounding errors. However, where the list of components is not exhaustive, the sum of the percentages of each such component may be less than 100% to provide a certain percentage for additional amount(s) of any additional component(s) that may not be explicitly described herein.

As used herein, the term "substantially" may refer to a quantity or entity, implying a large amount or proportion thereof. Where applicable in the context in which the term "substantially" is used, it may be understood in quantitative terms (with respect to any quantity or entity to which it refers in the context of the description), wherein a proportion of at least 80%, preferably at least 85%, more preferably at least 90%, most preferably at least 95%, particularly preferably at least 98%, such as about 100%, of the relevant whole is intended. By analogy, the term "substantially free" may similarly mean that the quantity or entity to which it refers contains no more than 20%, preferably no more than 15%, more preferably no more than 10%, even more preferably no more than 5% and most preferably no more than 2%, such as about 0%, of the relevant whole. Where appropriate (for example when specifying amounts of an ingredient), such percentages are preferably by weight.

Unless otherwise stated, all percentages listed herein are in wt%.

The present invention is further described with reference to specific examples, which are not limiting in nature.

Examples

Reference example 1

Making cocoa powder from cocoa pulp

Cocoa pods of the PH16, Salobrinho and CCN51 varieties were washed in running water. They were then immersed in chlorinated water containing 200 mg/L free chlorine for 10 minutes. They were then rinsed with chlorinated water containing 5 mg/L free chlorine by spraying.

The fruits were crushed by hand using stainless steel knives. The seeds in the pulp were then separated from the rind.

Pulp separation was performed on a commercial fruit crusher using a brush system. The pulp was collected directly into 40 x 50 cm polypropylene plastic bags, which were vacuum sealed. After packaging, the pulp was frozen and stored at -18°C.

Example A

First, the pulp was defrosted. Then, for enzymatic treatment, a batch of 3.0 kg of pulp was placed in a jacketed reactor and the temperature was raised to 42.5°C using a thermostatic bath, and when this temperature was reached, the enzyme (Pectinex® Ultra Clear, Novozymes) was added under the following conditions:

• Concentration: 1 ml enzyme / 100 g pulp

• Temperature: 42.5°C

• Reaction duration: 60 minutes

• Rotation 100 rpm

Shortly after enzymatic treatment, heat treatment was performed at 90°C for 5 min and cooled at 20°C. The cooled material was frozen for further lyophilization treatment.

Example B

After 60 minutes of the enzymatic reaction described in Example A, a sample was removed and sufficient calcium hydroxide was added to the pulp to adjust the pH to approximately 5.0. The following conditions were used:

adding 12.9 g Ca(OH)2 for every 3 kg of pulp (0.43%);

mixing with a mixer at 200 rpm for approximately 15 minutes; and then pasteurizing at 90°C for 5 minutes and cooling to 20°C.

The cooled material was frozen and sent for lyophilization.

Lyophilization of cocoa pulp was carried out on Lio Top equipment for 96 hours in two batches. In each batch, 2.5–3.0 kg were placed on each of the 8 trays.

After the freeze-drying process was completed, the trays containing the dehydrated pulp were removed from the equipment. The freeze-dried pulp was removed from the trays and placed into roll bags, which were then vacuum sealed to produce freeze-dried cocoa pulp powder.

Tests

Before lyophilization, the pH value of natural pulp, enzymatically treated pulp and dual-treated pulp was found to be 3.52 ± 0.32, 3.36 ± 0.02 and 4.77 ± 0.05 at 20°C, respectively, for the average value of two sets of measurements.

Viscosity measurements were made by averaging two sets of measurements using a Brookfields RVDV III rheometer at 30°C with rotation for 60 s.

Effective viscosity (100 rpm) and effective viscosity (250 rpm) for natural pulp were 611.5 ± 2.12 and 322.5 ± 3.53, enzymatically treated pulp 400.0 ± 14.14 and 162.5 ± 10.60 and pH-corrected enzymatically treated pulp 392.5 ± 12.43 and 158 ± 11.32 (all results are presented in centipoise).

Accordingly, it can be seen that the treatment of the present invention provides a reduction in viscosity.

The cocoa pulp powders from the above preparation example and Examples A and B were evaluated by HPAEC-PAD to determine sugar content using the following procedure.

Samples are dissolved in deionized water at pH above room temperature, heated at 70°C for 27 min, cooled, centrifuged and a diluted aliquot is prepared. The aliquot is syringe filtered with a 0.2 μm filter and the sugars are separated using a polystyrene-divinylbenzene anion exchange column with aqueous sodium hydroxide as eluent and the eluted carbohydrates are detected using PAD.

Sahara Example of preparation 1 / PH16 Example of preparation 1 / Salobrino Example 5 Example 6 DISACCHARIDES Lactose (g/100 g) Traces Traces Traces Traces Maltose (g/100 g) Traces Traces Traces 0.38 Sucrose (g/100 g) 14.75 28.19 3.91 2.26 MONOSACCHARIDES C6-SUGARS Fructose (g/100 g) 30.51 24.78 34.28 34.48 Fucose (g/100 g) Traces Traces Traces Traces Galactose (g/100 g) Traces Traces Traces Traces Glucose (g/100 g) 28.94 23.12 33.24 33.47 Rhamnose (g/100 g) Traces Traces Traces Traces Total sugar content (g/100 g) 74.2 76.09 71.43 70.59

Total sugars refer to measured sugars, e.g. does not include potentially present oligosaccharides.

In addition, frozen pulp obtained from Ricaeli was dried and evaluated as follows.

Total sugars in cocoa pulp samples were measured using high performance anion exchange chromatography with pulsed amperometric detection (HPAEC-PAD). Sugars from the samples were extracted into hot water and injected into the HPAEC-PAD system. Neutral sugars, which are weak acids, partially ionize at high pH and can be separated by anion exchange chromatography on a standard alkali-stable polymer column (CarboPac PA20). Sugars are determined by measuring the electrical current generated by their oxidation at the surface of a gold electrode.

Total dietary fiber and its fractions in cocoa pulp samples were measured by the enzymatic-gravimetric rapid integrated method for determination of total dietary fiber as described in Journal of AOAC International, Volume 102, Number 1, January-February 2019, pp. 196–207(12).

The protein content was determined by the Kjeldahl method, which involves digestion with sulfuric acid to decompose the organic compound and release nitrogen as ammonium sulfate. This is followed by distillation in the presence of sodium hydroxide to convert the ammonium to ammonia. The ammonia content, and therefore the nitrogen, is determined by titration. The amount of nitrogen is converted to protein by multiplying by a conversion factor of 6.25.

The lignin content of cocoa pulp was measured using the international AACC method 32-25.01.

Raw cocoa pulp mainly consists of mono- and disaccharides (79% w/w dry matter) and dietary fiber accounts for 6.5% of the pulp studied. Soluble high molecular weight fiber is the major component of the dietary fiber fraction in raw cocoa pulp followed by insoluble fiber. These results indicate that cocoa pulp fiber does not contain significant amounts of oligosaccharides provided that the average degree of polymerization (DP) of soluble high molecular weight fiber is ≥ 12 monosaccharide units (Okhuma et al., 2000. J AOAC Int. Volume 83, Number 4, Pages 1013–1019). In addition, a freeze-dried powder sample containing insoluble fiber and soluble high molecular weight fiber was analyzed by SEC-MALS. For this analysis, the sample was partially dissolved in DMSO and the results showed an average molecular weight of 9.5 kDa, corresponding to 50–60 DP.

% dry matter Total solids 14 (after drying) Lactose n/a Maltose 0.2 Sucrose 0.2 ± 0.2 Glucose 38.7 ± 0.1 Fructose 40.2 ± 0.1 Galactose n/a Total sugar content 79.3 Total dietary fiber content 6.58 ± 0.04 Insoluble dietary fiber 2.83 ± 0.15 Soluble dietary fiber is high molecular weight 3.36 ± 0.12 Soluble dietary fiber - low molecular weight 0.39 ± 0.00 Total protein (N x 6.25) 3.68 ± 0.3 Citric acid 9.5 Lignin 0

Reference example 2

30 g cocoa pulp from the same source as in Example 1 was added to the aluminum cup of a Rapid Viscosity Analyzer (RVA) and stabilized for 5 min at 40 °C with stirring at 50 rpm. Then 150 μl of liquid enzyme or 150 mg of powdered enzyme depending on the enzyme form were added. The stirring speed was increased to 960 rpm for 8 s and returned to 50 rpm, the temperature was maintained at 40 °C. The temperature was maintained at 40 °C for a further 45 min, after which it was increased to 90 °C to inactivate the enzyme for 10 min. The average viscosity was calculated as the average of the values obtained in the time interval from 41 to 49 min for each run. The viscosity reduction was calculated as the loss of viscosity compared to the untreated sample and expressed as a percentage.

Polygalacturonase activity was measured at 40°C by hydrolyzing polygalacturonic acid (Megazyme P-PGAT) at a concentration of 5.0 g/ml in 100 mM acetate buffer, pH 4.5. Samples were taken exactly after 2, 4, 6, 8, 10 and 12 min to plot kinetic curves. To stop the enzymatic reaction and stain the released reducing ends, DNS reagent solution (1% 3,3-dinitrosalicylic acid + 1.6% NaOH + 40% K Na tartrate tetrahydrate) was immediately added and the samples were boiled for 10 min. Finally, absorbance was measured at 540 nm. Galacturonic acid was used as a standard to plot the calibration curve.

Enzyme assay: Modified procedure of the CellG5 Endo-cellulase kit from Megazyme. Cellulase activity was measured at 37°C in 100 mM acetate buffer, pH 4.5, containing 1 g/L bovine serum albumin. The enzymatic reaction was stopped after exactly 2, 4, 6, 8, 10, and 12 min to construct kinetic curves by adding 2% TRIS buffer, pH 10.0. Finally, the absorbance was read at 405 nm. p-nitrophenol was used as a standard to construct the calibration curve. The average of 3 readings was used.

Enzyme Viscosity reduction/% Activity / PGN micromol/min/g Activity / cellulase / micromol/min/g Cellulosin GMY (HBI Enzymes Inc.) 96.3 475 2500 Cellulase FG conc. (EDC) 93.9 426 2380 Rapidase® Fiber (DSM) 73.3 2599 159 Pectinex® Ultra Clear (Novozyme) 72.7 10347 31 Rohapect® B1L (AB Enzymes) 72.4 9 333 Pectinex® UF(Novozyme) 71.7 3573 7 Pectinex® Ultra Color (Novozyme) 71.6 9609 42 Klerzyme 150 (DSM) 69.9 4342 43 Pectinex® Ultra SP-L (Novozyme) 69.8 3596 6 Cellulosin HC (HBI Enzymes Inc.) 68.6 122 514 Hemicellulase conc. (Sigma) 61.3 2311 142 Maxinvert L10000 (DSM) 4.79 0 0 Aromase® (Amano Enzyme Europe) 1.23 41 5

Example 1 (reference)

Unfermented, unroasted cocoa beans and cocoa pulp were pasteurized and mixed using a vacuum bowl cutter at 80°C for 20 minutes to form a paste. The paste was placed in trays and dried for 45 hours at 70°C. Using a Mettler-Toledo halogen moisture analyzer, the following water content results were obtained (available moisture % wt.):

After 22 h at 70°C = available moisture % wt. 16.66

After 27 h at 70°C = available moisture % wt. 5.40

After 45 hours at 70°C = available moisture % wt. 1.96

Dark chocolate was prepared using 1.8 kg sugar, 3.9 kg of the dried mass described above, 0.02 kg lecithin, 0.6 kg cocoa butter and 0.01 kg vanilla, mixed, conched and formed into a chocolate product.

Milk chocolate was prepared using 2.0 kg of dry milk, 2.5 kg of sugar, 1.2 kg of the dried mass described above, 0.02 kg of lecithin, 1.2 kg of cocoa butter and 0.01 kg of vanilla, mixed, conched and formed into a chocolate product.

Specifically, sugar and dried cocoa were mixed together and refined three times in a 3-cylinder Buehler refiner to reduce the particle size to 20 microns. Conching was carried out for 12 hours at 65°C for milk chocolate and 24 hours at 70°C for dark chocolate.

Example 2 (reference)

120 g of natural baker's yeast was added to 3 kg of pasteurized cocoa paste and placed in an oven at 30°C for 24 hours. The fermented mass was then roasted at 175°C for 40 minutes.

Dark chocolate was prepared using 1.8 kg sugar, 3.9 kg of the dried mass described above, 0.02 kg lecithin, 0.6 kg cocoa butter and 0.01 kg vanilla, mixed, conched and formed into a chocolate product.

Specifically, sugar and dried cocoa were mixed together and refined three times in a 3-cylinder Buehler refiner to reduce the particle size to 20 microns. Conching was carried out for 48 hours at 70°C.

Example 3 (reference)

Unroasted fermented isolated cocoa beans and cocoa pulp from Ricaeli were mixed (150 g:275 g) and processed in a food processor at full speed for 20 minutes. 300 g of the paste was tray dried for 24 hours at 70 °C. The dried mass was ground into pieces to form a powder. 229.5 g of the mass was mixed with 40.5 g of cocoa butter, refined and kept at 40 °C for 7 hours.

Example 4 (reference)

Non-fermented processed flakes (CPP flakes) were produced according to the following process. 20 kg of non-fermented pulp, beans, placenta were ground in a vacuum bowl cutter at 80°C for 20 minutes (to obtain a paste of pH 4.9), and then the pH was adjusted to pH 5.5 with KOH. The solid content was measured with a Mettler-Toledo halogen moisture analyzer at 105°C for 13 minutes to obtain a result of 72.9%.

The paste was then dried on trays in an oven at 75°C or 50°C to form flakes.

Drying time % Moisture Original 27.1 5 hours 18.2 20 hours 22.1 24 hours 19.5 Overnight at 50°C 14.0

The flakes were then transferred to a roasting oven and roasted at 120°C (measured product temperature) for 20 minutes. The roasting time was controlled by the appearance and taste of the flakes. The final product had a yield of 38%, a fat content of 38.83% and a moisture content of 3.97%.

Example 5 (reference)

Enzyme treated cereal flakes (CPP-flakes) were prepared according to the following method: 20.8 kg of unfermented pulp, beans, placenta were ground in a vacuum cutter with a rotating bowl at 80°C for 20 minutes (to obtain a paste pH 4.9).

Then the paste was treated with enzymes based on the mass% of the paste:

wt.% Enzymes 0.5 Cellulosin GMY 0.5 Pectinex Ultra Clear 0.5 Amylase AD11 MDP 0.5 AMG 1100 BG

100 g of each enzyme was measured into 3020 g of water and added to the paste. The mixture was left to stir in a mixer at low speed for 2 hours at 50°C. After the enzymatic treatment, a significant decrease in viscosity was observed, the paste was transformed into a thin homogeneous fluid. The increase in sweetness was also very noticeable.

The pH was adjusted to 5.5 using KOH.

The paste was then dried in trays in an oven at 75°C for 19 hours to form flakes.

The moisture content of the flakes at the end of the drying process was 8.3% (105°C for 13 min).

The flakes were then transferred to a roasting oven and roasted at 110°C (measured product temperature) for 15 minutes. The roasting time was controlled by the appearance and taste of the flakes. The final product had a yield of 32%, a fat content of 36.90% and a moisture content of 5.15%.

Example 6 (reference)

The chocolate mass recipes were based on 70% dark chocolate, which contains 70% cocoa solids (from all sources - including pulp and placenta), 48% fat and no emulsifiers. Batches of both cereals, enzymatically treated and non-enzymatically treated, were split in half to provide two versions of chocolate mass for each cereal type, with one half containing sucrose and the other containing cocoa pulp powder.

Example 6a

% % fat Refining Conching Final quantity Kg Kg Kg Farm-free flakes, CPP flakes 36,00 38.90 3,500 0,000 3,500 Sugar 30,00 0,00 2,917 0,000 2,917 Cocoa butter 34,00 100,00 0,700 2,606 3,306 Refined flakes 7,117 IN TOTAL AMOUNT 100,00 7,117 9,722 9,722 % sugar 30,00 % fat 48,00 29.0% % cocoa cake 70,00

Example 6b

% % fat Refining Conching Final quantity Kg Kg Kg Farm-free flakes, CPP flakes 36,00 38.90 3,500 0,000 3,500 Cocoa pulp powder 30,00 1.00 2,877 0,000 2,877 Cocoa butter 33.50 100,00 0,700 2,512 3,212 Refined flakes 7,077 IN TOTAL AMOUNT 100,00 7,077 9,589 9,589 % pulp cake 30,00 % fat 48,00 29.5% % cocoa cake 70,00

Example 6c

% % fat Refining Conching Final quantity Kg Kg Kg Ferm. CPP-flakes 35.30 36.90 3,497 0,000 3,497 Cocoa pulp powder 30,00 1.00 2,972 0,000 2,972 Cocoa butter 34.70 100,00 0,800 2,638 3,438 Refined flakes 7,269 IN TOTAL AMOUNT 100,00 7,269 9,907 9,907 % pulp cake 30,00 % fat 48.03 29.5% % cocoa cake 70,00

Example 6d

% % fat Refining Conching Final quantity Kg Kg Kg Ferm. CPP-flakes 35,00 36.90 3,497 0,000 3,497 Cocoa pulp powder 30,00 2,997 0,000 2,997 Cocoa butter 35,00 100,00 0,850 2,647 3,497 Refined flakes 7,344 IN TOTAL AMOUNT 100,00 7,344 9,991 9,991 % pulp cake 30,00 % fat 47.92 29.1% % cocoa cake 70,00

The method from Example 1 was used to obtain chocolate, with the difference that the conching temperature was 40°C.

Cocoa pulp powder was obtained by the method of WO 2019149909, example 14.

The particle size of the flakes used in Examples 6a and 6b was measured using a Malvern Mastersizer 2000 particle size analyzer, Scirocco 2000 method with dry binders according to the Fraunhofer light diffraction theory after refining on a 3-roll refiner. In Example 6a, the D90 was 16 microns and in Example 6b, 38 microns.

Enzymatic treatment has been shown to reduce viscosity during the conching stage. However, all samples were homogeneous. The enzymatic process has also been shown to increase sweetness. It should be noted that the drying and roasting processes can affect the amount of final sugars due to caramelization and Maillard reactions.

Example 7 (reference)

As mentioned above, the aim of the present invention is to utilize all the internal components of the cocoa fruit, which typically comprises 77% husk, 13% bean, 8% pulp and 2% placenta. The composition of cocoa puree made from beans, pulp and placenta was analyzed and the results are shown in Table 10. It was shown to contain approximately 8% sugar (> 90% fructose and glucose in a ratio close to 1:1), 13% fat, 6.5% fiber (85% insoluble fiber), 4.5% protein and 62% moisture. The pH of the cocoa puree is 4.9.

Cocoa puree % (wet weight) % (dry weight) Cocoa beans 55.0 80.0 Cocoa pulp 35.0 15.0 Placenta 10.0 5.0

Fermented CPP, dark 70% + pulp powder Cocoa pulp powder CPP flakes Cocoa butter Total (%) Batch 841643
NQAC Results 30.0% 35.3% 34.7% % Fat 0.30 11.41 34.70 46,41 46.32 Squirrels 1.50 4.52 0,00 6.02 6.29 Total sugar content 17.70 4.97 0,00 22.67 21.75 Fructose 9.30 2.70 0,00 12.00 11.69 Glucose 8,10 1.75 0,00 9.85 9.57 Sucrose 0.30 0.34 0,00 0.64 0.49 Total dietary fiber content 5.01 4.04 0,00 9.05 10.1 TIF 3.01 2.15 0,00 5.16 5.62 TSF 2.00 1.89 0,00 3.89 4.48 Organic acids Energy Moisture 1.20 2.19 3.39 3.38

The calculated composition of the chocolate recipe with enzymatically treated CPP and cocoa pulp powder was calculated based on the composition of their ingredients. The calculated composition shows very good agreement with the analytical results. This also indicates that the chocolate composition was not changed by the chocolate manufacturing process.

Example 8

The above described enzyme combination treatment was carried out on a combination of cocoa powder and cocoa pulp as follows.

Enzymatic treatment was carried out according to the following method:

1. Ricaeli cocoa pulp and Barry Callabo cocoa powder with 10-12% fat were mixed at 800 rpm

2. The pH was adjusted to 4.5 by adding 15 M (56%) potassium hydroxide.

3. Added both Pectinex Ultra Clear and Cellulosin GMY

4. Incubated for 1 hour at 40°C

5. Increased pH to 5.5 and temperature to 60°C

6. Added both amylase AD11MP and amylolucosidase 1100 BG

7. Keep for an additional 2 hours at 60°C

8. Transfer the product into a bottle and inactivate the enzymes by autoclaving the product.

for 15 min at 95°C

The quantities used are given below.

Enzymes - Low Dose Enzymes - high dose Cocoa pulp 260 g 260 g Cocoa powder 40 g 40 g Pectinex Ultra Clear 0.65 g 1.3 g Cellulosin GMY 0.65 g 1.3 g Amylase AD11MP 0.2 g 0.4 g AMG 1100 BG 0.2 g 0.4 g

Example 9

The above-described combined enzyme treatment was carried out on a combination of cocoa powder and cocoa pulp/cocoa liquor as follows.

The reference and control tests were carried out according to the following process:

1. Add cocoa pulp to the Polylave reactor

2. The pH was adjusted to 4.5 by adding 15 M (56%) potassium hydroxide.

3. Heat to 60°C while stirring.

4. Dissolve all the enzymes in water and add to the cocoa pulp

5. Keep for 1 hour at 60°C with stirring

6. Add cocoa powder/cocoa mass

7. The pH was adjusted to 5.5 by adding 15 M (56%) potassium hydroxide.

8. The enzymes were inactivated by heating for 10 min at 95°C with stirring.

9. Cool to below 65°C and transfer to a 2L bottle

The samples were tested according to the following process:

1. Mix cocoa pulp and cocoa powder/liquor in a Polylave reactor

2. The pH was adjusted to 4.5 by adding 15 M (56%) potassium hydroxide.

3. Heat to 60°C while stirring.

4. Dissolve all enzymes in water and add to the previous mixture.

5. Keep for 1 hour at 60°C with stirring

6. The pH was adjusted to 5.5 by adding 15 M (56%) potassium hydroxide.

7. The enzymes were inactivated by heating for 10 min at 95°C with stirring.

8. Cool to below 65°C and transfer to a 2L bottle

The recipes are given below (quantities in g):

Ingredient Reference Example 9a Control Cocoa pulp 1814 1737 1737 Cocoa powder 186 263 263 Cellulosin GMY 9.1 8.7 8.7 Pectinex Ultra Clear 9.1 8.7 8.7 Amylase AD11MP 2.6 AMG 1100 BG 2.6 Water 35 35 35 Ingredient Reference Example 9b Control Cocoa pulp 1648 1521 1521 Cocoa mass 352 479 479 Cellulosin GMY 8.2 7.6 7.6 Pectinex Ultra Clear 8.2 7.6 7.6 Amylase AD11MP 3.0 AMG 1100 BG 3.0 Water 34 34 34

Example 10

The reference test was carried out according to the following method:

1. Introduced cocoa pulp into a double-jacketed tank

2. The pH was adjusted to 4.5 by adding 15 M (56%) potassium hydroxide.

3. Heat to 60°C while stirring.

4. Added enzymes to cocoa pulp

5. Keep for 1 hour at 60°C with stirring

6. The enzymes were inactivated by heating for 10 min at 95°C with stirring.

7. Evaporated using an Okawara rotary cone evaporator (heating temperature = 70°C/

Product temperature = 40°C)

8. Add cocoa powder

9. The pH was adjusted to 5.5 by adding 15 M (56%) potassium hydroxide.

10. Dry using a Niro SD 6.3 spray dryer (65°C/ with a bifluid nozzle, can also be done using a rotating disc atomizer)

For Examples 10a and 10b, cocoa pulp or cocoa liquor was added in Step 1 and Step 8 was omitted. Step 7 was not used for Example 10b.

Ingredient Reference Example 10a Example 10b Cocoa pulp 50 kg 50 kg 50 kg Cocoa mass 15.75 kg Cocoa powder 4.6 kg 7 kg Cellulosin GMY 125 g 250 g 250 g Pectinex Ultra Clear 125 g 250 g 250 g Amylase AD11MP 67 g AMG 1100 BG 67 g

The chocolates were obtained according to the following procedure:

The cocoa butter was melted in an oven at 65°C and sufficient was cooled to 30°C before adding to the spray dried powder and mixing at room temperature using a Kenwood kitchen mixer. The resulting mixture was refined twice with decreasing clearance between cylinders: 5 and 3.

The second part of cocoa butter was gradually added to the purified powder and mixed at 42°C for 1 hour. The chocolate mass was then cooled with the addition of seeds from the butter at 35°C. After reaching a temperature of 28°C, the chocolate was poured into preheated moulds (24°C) and left in the refrigerator for 1 hour before removing from the mould.

Ingredients/g Reference Example 10a Example 10b Reference powder 579.2 Example 10a Powder 550.7 Example 10b Powder 868.1 Cocoa butter 240 240 Refining Cocoa butter 240 240 200 Cocoa Butter Seeds 1.06 1.03 1.05

Example 11

This cohydrolysis of cocoa pulp and cocoa powder using 0.5% each of Pectinex Ultra Clear and Cellulosin GMY was calculated in comparison with wet pulp using 1.0% each of AD11MP amylase and 1100 BG amyloglucosidase and in comparison with cocoa powder.

Three different products were prepared according to the flow chart shown in Fig. 1

Reference: When only cocoa pulp was treated with pectinase and cellulase, cocoa powder was added afterwards according to the chocolate composition containing 48% cocoa butter, 30% cocoa pulp and 22% defatted cocoa powder.

Example: When cocoa pulp and cocoa powder were co-hydrolyzed using pectinase, cellulase, amylase and amyloglucosidase. The pulp/powder ratio was determined for chocolate consisting of 48% cocoa butter, 25% cocoa pulp and 27% defatted cocoa powder.

Control: When only cocoa pulp was treated with pectinase and cellulase, and cocoa powder was added afterwards according to the chocolate composition consisting of 48% cocoa butter, 25% cocoa pulp and 27% defatted cocoa powder.

The process was repeated for cocoa mass (Fig. 2).

Sugar levels were measured, in the example it was the highest.

Sensory panel 12 was used to evaluate the sweetness of cohydrolyzed cocoa pulp and cocoa powder/liquor. A ranking test was used to differentiate samples based on their sweetness without rating the 0–10 intensity scale. For this purpose, the samples were presented to the panelists simultaneously and asked to rate them on a scale from least sweet to sweetest. The panelists performed the ratings twice, obtaining a total of 24 ratings.

The sensory evaluation of liquid products correlated perfectly with sugar level, confirming that glucose released from cocoa powder due to cohydrolysis can enhance the sweetness perception in liquid cocoa, making liquid cocoa significantly sweeter compared to the reference (containing 30% cocoa pulp).

Example 12

Three variants were obtained (see block diagrams in Fig. 3):

A standard with enzymatically hydrolyzed cocoa pulp with the addition of cocoa powder before drying to achieve 30% pulp in the final chocolate.

Example of powder 12a with cohydrolysis of cocoa pulp and cocoa powder in a ratio corresponding to 25% pulp in the final chocolate.

Example of cocoa mass 12b with cohydrolysis of cocoa pulp and cocoa mass in a ratio corresponding to 25% pulp in the final chocolate.

Pectinex Ultra Clear and Cellulosin GMY were added at 0.25% each, compared to wet pulp as a reference. Amylase AD11MP and amyloglucosidase 1100 BG were added at 1%, compared to cocoa powder or equivalent in cocoa liquor.

After enzymatic hydrolysis and enzyme inactivation, an evaporation step was performed to reduce the amount of water removed during spray drying.

Sugars were analyzed in the resulting spray-dried powders - reference - 43 wt.% glucose and fructose (21 wt.% glucose and 22 wt.% fructose), example 12a - 41 wt.% glucose and fructose (21 wt.% glucose and 20 wt.% fructose) and example 12b - 31 wt.% glucose and fructose (15 wt.% glucose and 16 wt.% fructose)

The chocolate was prepared as described above. Organoleptic evaluation of the resulting chocolate did not show significant differences between samples, which confirms the possibility of reducing cocoa pulp from 30 to 25% without affecting sweetness. Increased sweetness due to enzymatic treatment is noticeable, especially in the cohydrolyzed cocoa mass sample.

Claims (21)

1. A method for producing a chocolate product comprising obtaining a material obtained from a cocoa-based substrate, comprising the following steps: i. treating a cocoa-based substrate with at least one enzyme, wherein the cocoa-based substrate is selected from cocoa powder and/or cocoa mass; ii. treating cocoa pulp with at least one enzyme, wherein the method comprises mixing cocoa pulp and a cocoa-based substrate; iii. drying stage; and iv. mixing the dried product with cocoa butter, wherein at least one enzyme in step i. is selected from amylases and at least one enzyme in step ii. is selected from at least one cellulase and/or at least one pectinase. 2. The method according to claim 1, wherein at least one enzyme in step i. is selected from amyloglucosidase, glucoamylase and alpha-amylase. 3. The method according to claim 1 or 2, wherein at the drying stage a dried mixture is obtained containing less than 10.0% by weight of water. 4. The method according to claim 3, wherein the mixture contains from 40 wt.% to 95 wt.% pulp and from 5 wt.% to 60 wt.% cocoa-based substrate. 5. The method according to any one of claims 1 to 4, wherein the total amount of enzyme used is from 0.10 to 20% of the total weight of the substrate and cocoa pulp, preferably from 0.20 to 10%, more preferably from 0.5 to 5.0%. 6. The method according to any one of claims 2 to 5, wherein the enzyme mixture comprises cellulase, pectinase, alpha-amylase and amyloglucosidase. 7. The method according to any one of claims 1 to 6, wherein the cocoa-based substrate and cocoa pulp are mixed prior to treatment with the enzyme. 8. The method according to any one of claims 1 to 7, wherein the enzyme treatment steps in steps i. and ii. are parallel or sequential. 9. The method according to any one of paragraphs 1–8, which includes: enzymatic treatment of a mixture of cocoa pulp and cocoa powder and/or cocoa mass, wherein a mixture of enzymes is used for the enzymatic treatment, which contains at least one cellulase, at least one pectinase and at least one amylase, wherein the total amount of the enzyme mixture used is from 0.10 to 20% of the total mass of the cocoa pulp and cocoa powder and/or cocoa mass, and the amount of each individual enzyme independently is from 0.025 to 5.0% of the total mass of the cocoa pulp and cocoa powder and/or cocoa mass. 10. The method according to any one of claims 1 to 9, wherein the enzymatic treatment conditions are from 30 minutes to 1.5 hours at a temperature from 55°C to 75°C; and at a pH from 4.0 to 5.5. 11. A method for producing a chocolate product, comprising the method according to any one of claims 1 to 10, additionally mixing with ingredients selected from the group containing sugar, an emulsifier, milk-based ingredients and flavouring additives and mixtures thereof. 12. A chocolate product produced by the method according to any one of claims 1 to 10, containing cocoa butter and from 20.0 wt.% to 90.0 wt.% of a mixture of enzyme-treated cocoa pulp and enzyme-treated cocoa-based substrate. 13. The chocolate product of claim 12, wherein the mixture of enzyme-treated cocoa pulp and enzyme-treated cocoa-based substrate comprises from 5 wt.% to 60 wt.% cocoa-based substrate.