BG113438A - Industrially manufactured, new chocolate ball with a long shelf life and production method thereof - Google Patents

Abstract

The invention relates to a long shelf-life chocolate ball which is suitable for industrial production, as it differs from other confectionery products, and to its method of production. In particular, the invention comprises a hollow ball of steamed dough, a filling material and a structure of cream (chocolate - chocolate composition) covering the entire structure, which allows products such as profiteroles and eclairs, which belong to the field of confectionery and which are more expensive than standard desserts, to find a place on the shelves with serial production.

Description

INDUSTRIALLY MANUFACTURED CHOCOLATE BALL WITH A LONG SHELF LIFE AND METHOD FOR ITS PRODUCTION

Technical area

The invention relates to a chocolate ball with a long shelf life, which is suitable for industrial production, as it differs from other confectionery products, and to the method of its production. The invention consists in particular of a hollow ball of steamed dough, a filling material and a creamy structure (chocolate-chocolate composition) covering the entire structure, which allows products such as profiteroles and eclairs which belong to the field of confectionery and which are more -more expensive than standard desserts to find a place on the shelves with mass production.

Prior art

Food products coated with chocolate on the outside and with a cream filling inside them, which are called chocolate balls, are a type of dessert that is prepared by mixing basic ingredients such as flour, margarine, water and eggs, by baking this mixture at a predetermined temperature and by filling with filling materials such as cream etc. in the baked dough. To enrich the taste, milk and different types of additives, different thickeners and leavening agents can be added during the production phase in these products, similar products that are known to belong to French pastries. The complete characteristic of the product to be obtained at the end of the production process is determined by the type of material used and the temperature values and duration values of the firing process applied.

The state of the art requires the outer part of the dough balls to form a shell during the baking process by baking the prepared dough mixture at a certain temperature (temperature between 100-200°C) for a certain duration (4-20 minutes) and the internal structure to be volumetrically hollow. Thus, mass production of chocolate balls with the type of material and according to the specified production method, according to the demand and supply for sale after packaging, is an important commercial item in the food industry.

In the modern state of the art, ganache (cake cream) is used as the filling material inside the chocolate-covered balls, and flour, margarine, water, sugar, and eggs are used in the cookie portion. The products use flavors such as the aforementioned chocolate, coffee, orange, peanut, rose, berry, vanilla and caramel. Due to its basic content and the characteristics of the filling material, chocolate-covered filled products are not long-shelf-life products that can be found packaged in stores, except for pastry shops, which makes them high-priced products.

In the current state of the art, there are many patents related to filling and chocolate coating products and technologies for their production. No patents have been found relating to the production method of the products used in the said production method, which have a long shelf life and are industrially developed, and which have a correct shape and do not deform over time, thanks to the novelty of the production method and content used in said chocolate-covered and cream-filled balls.

South Korean patent K.R20020076435 describes a ball-shaped chocolate-covered product that is made from a pastry made from rice flour. In the mentioned patent, the powdered mixture consisting of rice flour, eggs, sugar and flavoring additive is baked and its exterior is coated with a finished liquid chocolate mixture. It is a practical product that people can prepare easily. However, a new type of chocolate-covered ball with filling that is suitable for industrial production and has a long shelf life, as well as the method of its production, are not described in the said patent.

South Korean patent KR20130071513 describes a filled ganache confectionery that is in the form of a ball made using a chocolate mold and has a layer of rice dough inside. However, a new type of chocolate-covered ball with a filling that is suitable for industrial production and has a long shelf life, as well as the method of its production, are not described in the said patent.

Japanese patent JP2001197864 describes a composition that is prepared for chocolate covered confectionery products. The characteristic of the product described in the said patent is that it is a product that can be applied to confectionery covered with a chocolate mixture. However, a new type of chocolate covered ball is a filling that is suitable for industrial production and has a long shelf life, as well as the method of its production, are not described in the said patent.

Japanese patent JPH06181690 describes a multilayer product covered with chocolate. The characteristic of the product described in the said patent is that it is a product that is covered with a chocolate mixture and has layers of liquid and non-liquid chocolate parts. However, a new type of chocolate-covered ball with a filling that is suitable for industrial production and has a long shelf life, as well as the method of its production, are not described in the said patent.

Said patents describe various methods of making chocolate covered balls with filling and the products produced by said methods; however, they do not describe a new filled chocolate covered ball that is similar to the product of the present invention, has a long shelf life and is suitable for industrial production, and the method of its production.

Technical essence of the invention

In the new product, a chocolate-covered ball with filling, and the method of its production according to the invention, it is aimed to produce the ball or similar food products consisting of steamed dough and cream by a new method suitable for industrial production and ensuring a long shelf life of validity; to be packaged using packaging machines or different packages after their production so that they can find space on the shelves for a long period of time; and to be able to produce similar new products. The chocolate covered ball with filling according to the present invention can remain on the shelves for a period of 6 months and can be consumed within this period by the end user. This produces a product that is cheap, readily available and beneficial to the end user.

In the current state of the art, the main method of manufacturing the product, a chocolate covered ball with filling, involves the steps of: first, injection molding the steamed dough prepared by mixing flour, sugar, eggs and water into small balls; then baking the steamed pastry injected onto a pan, filling the inner hollow part of the baked steamed pastry with cream (it can have different shapes), and covering its outer part with chocolate. After these processes, the said product is ready for packaging.

The first advantage of the production method of the present invention is that it allows serial production thanks to known parameters determined by the invention, since the structure of the steamed dough is very delicate, which was not possible in the past.

Another advantage of the present invention is that it allows to produce products with a long shelf life and without deformation of the shape during its shelf life, which cannot be ensured with the chocolate covered balls with filling produced by conventional methods .

Another advantage of the present invention is that the product can be obtained at a price suitable for the customer due to its serial production.

Another advantage of the present invention is that it is a production method that allows shortening the duration of rising and baking, providing the desired characteristics of the steamed dough.

Another advantage of the present invention is that there are technical pasteurization systems developed for the cream filling with which the steamed dough is filled.

For foods with low moisture content, such as chocolate-covered balls with filling and similar products, storage conditions are the parameters that directly affect product quality. The state of the art does not mention solutions regarding the deformation of the shape of the products according to the storage conditions.

The drawings will aid in a better understanding of the method and the product produced by the method of the present invention.

Description of the drawings

Fig. 1a shows the schematic form of the processes and phases through which the main ingredients of the chocolate covered balls with filling of the present invention pass.

Fig. 1b is a cross-sectional view showing the filling and shell portions of the chocolate ball product produced by the method of the present invention.

Fig. 2 is the production flow chart of the chocolate ball product produced by the method of the present invention.

Section and part reference numbers to serve to describe the invention

1- Steamed dough a- Powder composition

1b- Steamed dough c- Outer shell of the steamed dough

Id- Cavity in the steamed dough

2-Material for inner filling-ganache

2a-Chocolate wrapper

H-Chocolate ball

The steps of the present invention indicated in Figure 3 are as follows:

-Preparing the steamed dough (210)

-Transfer the steamed dough mixture to an injection molding machine and injection molding the mixture (220)

-Baking the steamed dough (230)

-Cream preparation and cooking (240)

- Cream filling in the steamed dough (250)

-Coating the outer shell of the baked steamed pastry with chocolate (260)

-Cooling (270)

-Packaging (280).

Exemplary embodiment of the invention

In the new product, namely a ball covered with chocolate and filled with cream, and the method of its production according to the invention, it is intended to produce the ball or similar food products consisting of steamed dough and cream by a new method suitable for industrial manufacturing and ensuring a long shelf life; be packaged using separator packaging machines or different packaging after production so that it can be stored on the shelves for a long period of time; and to be able to produce similar new products. The chocolate covered and cream filled ball product according to the present invention can remain on the shelves for a period of 6 months and can be consumed within this period by the end user. This produces a product that is cheap, readily available and beneficial to the end user.

According to the invention, in the production method of the product, a ball covered with chocolate and filled with cream, with a long shelf life and suitable for industrial production, the main ingredients used are mainly flour, margarine, sugar, water, additives (emulsifiers , thickeners and preservatives, etc.) and eggs. In the said product, a chocolate-covered and cream-filled ball, chocolate, coffee, orange, peanut, rose, berry, vanilla and caramel can be used as flavors in the cream for the inner filling. Cocoa liquor, vegetable oil, sugar, emulsifier, and cocoa powder are used as the main ingredients in making ganache, which is the cream used to fill the cavities of steamed cookies.

In fig. 1 shows a schematic perspective view of the product, a chocolate-covered, cream-filled ball that has a long shelf life and is suitable for industrial production. Fig. 2 shows the block diagram showing the main stages of the production process of a chocolate-covered and cream-filled ball according to the invention.

The chocolate ball product (3), which is produced by the method of the present invention, consists of an outer shell of steamed dough (1c) and a chocolate shell (2a) covering the outer shell, and an inner ganache filling material (2) filled in the cavity formed in the steamed dough (1 d) inside said outer shell of steamed dough (1c).

In the described method, the manufacturing step begins with the step of preparing the powdered content (1a), as described in the process diagram of FIG. 2. First, the powder content (1a) mentioned above, ie. flour and sugar, weighed in certain grams and mixed. The homogenized powder content (1a) is mixed again by adding it to the previously prepared mixture of water and margarine, then the resulting dough is mixed again by adding the eggs to make a steamed dough (1b). The steamed dough (1b) is then injected onto trays in the form of balls, preferably weighing 5 to 15 grams.

The steamed dough (1b) and the outer shell of the steamed dough structure (1c) do not have a special leavening agent. The mentioned steamed dough (1b) contains only flour, margarine, sugar, water, various additives (emulsifiers, thickeners and preservatives, etc.) and eggs. The steamed dough (1b), preferably of different colors, prepared by adding the said additives, is transferred to an injection molding machine and injected into various shapes on trays, and subjected to the baking process by being put into the oven after the process of leavening which takes place after the injection molding process based on the process conditions. The optimum baking temperature used to produce the chocolate ball product (3) is preferably between 150°C and 250°C (degrees Celsius), and the baking period is preferably between 8 and 25 minutes. Dough (1b) acquires its structural properties during the baking process. The outer part should form the outer shell of the dough (1 c), the inner part should be hollow and not sticky when baked, and the outer shell of the baked dough (1 c) should be medium firm.

After finishing the baking process of the outer shell of the dough (1c), the optimal parameters for preparation and pasteurization of the internal filling material-ganache cream (2) are determined, with which to fill the cavity in the steamed dough (Id). These parameters are water activity, humidity, density, etc. The production of the internal filling-ganache (2) in the form of a flavored pudding (vanilla, milk, cream, etc.) is carried out by mixing vegetable oil, flour, sugar, eggs, margarine, milk and their derivatives in predetermined percentages for the preparation of the cream and cook at a temperature in the range between 80-100°C. After this step, the inner ganache filling (2) is filled into the cavity of the steamed dough (Id) inside the outer shell of the steamed dough (1c). Then the chocolate or chocolate composition product, which is the prepared chocolate coating material (2a), is poured on top of the steamed dough shell (1c) into which the inner ganache filling material (2) is filled and as a result of these steps, a chocolate ball (3) is produced, which is the final product, with a shelf life of 6 months.

The interactions between the inner ganache filling (2) and the outer steamed dough shell (1c) determine the quality of the product. Thanks to this invention, the disadvantages can be eliminated. The chocolate ball (3), which is the final product, is transferred onto the packing belt by 3 man or machine. After this step, packaging is done and the products are delivered to the end users. When the production method of the chocolate ball, which has a long shelf life and is suitable for industrial production, is considered as a complete process, it includes the following stages:

-Preparing steamed dough (210)

-Transfer the steamed dough mixture to an injection molding machine and injection molding the mixture (220)

-Baking the steamed dough (230)

-Cream preparation and boiling (240)

- Cream filling in the baked steamed dough (250)

-Coating the outer shell of the steamed dough with chocolate (260)

-Cooling (270)

-Packaging (280)

What steps these stages involve is described below:

Preparation of the steamed dough (210): In the developed production method, first the powder content (1a) specified for the production of the chocolate ball (3), namely flour and sugar, is weighed and sifted. After ensuring the homogeneity of the sifted powder content (1a), the main step of turning it into a steamed dough (1b) is carried out.

The mentioned steamed dough (1b) consists only of flour, margarine, sugar, water, various additives (preservatives, thickeners and emulsifiers) and eggs. When making the structure of the steamed dough, margarine and water are preferably heated to a temperature of 60-90°C, after which the powdered content (1a) is added to them, i.e. flour and sugar, and the mixture is cooked by heating preferably to a temperature of 80-100°C. After the cooking process, the dough looks like cake batter. The dough is cooled to a temperature of 40-50°C and eggs are added to the dough mixture to form a steamed dough and obtain a steamed dough with the desired properties. After adding the eggs, the mixture is stirred and a soft and low-viscosity steamed dough is obtained (1b). Said steamed dough (1b) does not have a special leavening agent.

Transfer of the mixture to the injection molding machine and injection molding of the mixture (220): At this stage, the steamed dough (1b) is transferred to an injection molding machine and injected onto the trays in the form of small balls, preferably weighing 5 and 15 grams. The injection molded parts are preferably in the form of round balls.

Baking the steamed dough (230): At this stage, the dough (1b) injected onto the trays is baked by a suitable baking method to ensure the desired shape and to have a hollow and fluffy structure. The optimum baking temperature used to produce said chocolate ball product (3) preferably varies between 150°C and 250°C (degrees Celsius), and the baking period is preferably between 8 and 25 minutes. Steamed dough (1b) acquires its structural properties during the baking process. When the outer part, which is the outer shell of the dough (1c) is baked, and the inner part becomes hollow and non-sticky, the baking process of the dough (1) ends.

Preparation and cooking of the custard (240): At this stage, the custard with which the cooked dough (1) is to be filled, namely the inner ganache filling (2), is prepared by a special process. The cream can be prepared in the form of a pudding, optionally flavored (milk, vanilla, berries). The cooking process takes place after the main ingredients used to make the cream are mixed homogeneously. The production of the internal filling material-ganache (2) in the form of a flavored pudding (vanilla, milk, cream, etc.) is carried out by mixing vegetable oil, flour, sugar, eggs, margarine, milk and their derivatives in predetermined percentages for preparation of the cream and by cooking at a temperature between 80-100°C. Thanks to the special techniques (pasteurization, etc.) used for creams, the quality of the product is further improved.

Filling the cream in the steamed dough (250): After the baking process of the steamed dough (1) is completed, the cream, namely the inner filling material-ganache (2) is filled into the cavity in the steamed dough (1 d), which is the part between the outer dough shell (1) and the dough core (1).

Covering the outer shell of the steamed dough with chocolate (260): After filling the cavity in the steamed dough (Id) with the inner ganache filling (2), the outer shell of the steamed dough (1c) is covered with chocolate couverture (2a), preferably chocolate or a chocolate composition, and as a result of this step, the chocolate ball (3), which is the final product, is produced to have a 6-month shelf life.

Cooling (270): The resulting chocolate ball (3) passes through the cooling tunnel and the product takes its final shape. After this step, the chocolate ball products (3) are transferred onto the packaging belt and packaged.

Packaging (280): The final product, namely the chocolate ball (3), is transferred to the packaging belt by humans or by machine. After this step, packaging is done and the products are transported to the end users.

Industrial applicability of the invention

According to the invention, the new product, a ball covered with chocolate and filled with cream, and the method of its production, it is intended that the ball or similar food products consisting of steamed dough and cream be produced by a new method suitable for industrial production and having long shelf life; be packaged using separator packaging machines or different packaging after production so that they can be kept on the shelves for a long period of time and similar new products can be produced.

The chocolate ball product of the present invention has a 6 month shelf life and can be consumed within this period by the end user. By developing the manufacturing method of said product, a product is produced that is cheap, readily available and beneficial to the end user. The possibility to choose different types of fruit flavors, additives and syrups provides a wide product range that will allow the production of profiteroles, eclairs and similar foods with a long shelf life.

Claims (9)

1. A method for producing a chocolate ball product that can be used in the food industry, has a long shelf life and is suitable for industrial production, characterized by the following stages: Preparation of steamed dough (210); Transferring the steamed dough mixture to an injection molding machine and injection molding the mixture (220); Baking the steamed dough (230); Preparation and cooking of cream (240); Cream filling in the steamed dough (250); Covering the outer shell of steamed dough with chocolate (260); Cooling (270); Packaging (280). 2. A method according to claim 1, characterized in that in the step of preparing the steamed dough (210), the flour, which is specified as powder content (1a) for the production of the chocolate ball (3) and the sugar are weighed in predetermined grams; sieved to ensure homogeneity; then the flour and sugar are added as a powdered content (1a) after heating the margarine and water, preferably at a temperature of 60-90°C, to obtain a steamed dough (1b); said mixture is cooked by heating preferably to a temperature of 80-100°C; after the cooking process, the temperature of the dough is preferably cooled to 40-50°C; eggs are added to the dough mixture to obtain a dough with the desired properties; and the mixture is stirred to obtain a low viscosity dough. 3. A method according to claim 2, characterized in that in the step of transferring the mixture to an injection molding machine and injection molding the mixture (220), the steamed dough (1b) is transferred to the injection molding machine and injection molded onto the trays in the form of small balls preferably weighing 5 and 15 grams. 4. A method according to claim 3, characterized in that in the step of baking the steamed dough (230), following the injection process of the steamed dough (1b) injected onto the trays, the steamed dough (1b) is transferred to an oven and subjected to a baking process under certain conditions by heating preferably at a temperature of 150-250°C (degrees Celsius) and preferably for a baking period between 8 and 25 minutes; and the steamed dough (1b) acquires the desired shape (1) by baking. 5. Method according to claim 4, characterized in that in the stage of preparation and cooking of the cream (240), the production of the internal filling material-ganache (2) with flavor (vanilla, milk, cream, etc.) is carried out by mixing vegetable oil, flour, sugar, eggs, margarine, milk and their derivatives for the preparation of the cream and by cooking at a temperature, preferably between 80-100°C; and thanks to the special techniques (pasteurization, etc.) used for creams, the quality of the product is further improved. 6. Method according to claim 5, characterized in that at the step of filling the cream in the steamed dough (250), after the baking process of the steamed dough (1) is completed, the internal filling material - ganache cream (2) is filled in the cavity in the steamed dough (1 d), which is the part between the outer shell of the steamed dough (1) and the core of the steamed dough (1). 7. Method according to claim 6, characterized in that in the step of covering the outer shell of the steamed dough with chocolate (260), the chocolate couverture (2a), preferably chocolate or a chocolate composition, is poured over the outer shell of the steamed dough (1c), and this step results in the chocolate ball (3), which is the final product. 8. Method according to claim 7, characterized in that in the cooling step (270), the obtained chocolate ball (3) passes through a cooling tunnel. 9. Method according to claim 8, characterized in that in the packaging step (280), the final product, namely the chocolate ball (3), is transferred onto the packaging belt, preferably by humans or by machine; and packing is done.