WO2009024441A1

WO2009024441A1 - Fat-based coating for frozen confection with texture like hard candy

Info

Publication number: WO2009024441A1
Application number: PCT/EP2008/059995
Authority: WO
Inventors: Michael Lee Talbot; Mary Cheryl Millete Soledad
Original assignee: Nestec SA
Current assignee: Nestec SA
Priority date: 2007-08-22
Filing date: 2008-07-30
Publication date: 2009-02-26
Anticipated expiration: 2010-02-22
Also published as: AR068003A1

Abstract

The present invention relates to a fat-based coating that has a texture like hard candy. The fat-based coating composition may be applied to a frozen confection by dipping, enrobing or spraying/ showering that when set resembles a hard candy layer.

Description

FAT-BASED COATING FOR FROZEN CONFECTION WITH TEXTURE LIKE HARD CANDY

FIELD OF THE INVENTION

The present invention primarily relates to a fat-based coating for frozen confection that has a texture similar to hard candy and to the production of frozen confections with such coatings.

BACKGROUND OF THE INVENTION

Frozen confections are desirable products, particularly for consumption on hot days, but skilled artisans continually look to improve upon such products or to add additional features to make them even more desirable. Various combinations of sweets or candies and ice confections are known, but certain combinations are very difficult, if not impossible, to manufacture.

For example, U.S. Patent No. 6,759,079 discloses an edible confectionery product that has at least two parts: a first part, which is a base unit formed of a first confection and having a top, a bottom, and between five to twelve sides when viewed from above, and a second part, which is a center inclusion formed of a second confection that is partially embedded in the base unit. The base unit forms a mold into which the center inclusion is held or provided. The center inclusion can be an ice confection and while hard candy is disclosed, it is used as an alternative to a center inclusion rather than as the base unit or as a coating.

Coating a frozen confection with hard candy presents a number of challenges. First, to coat a frozen confection, such as an ice cream bar, with a continuous layer of real hard candy would require the confection to be dipped in, enrobed in (i.e., passed through, a falling curtain of) or sprayed/showered with hard candy at a temperature sufficiently high for the candy to be liquid, and usually greater than 143°C/290°F. Frozen desserts typically melt at temperatures in excess of about -20°C/-4°F. Thus, one of the problems associated with this method would be the melting of the frozen dessert when it comes into contact with the hot molten candy. Second, melting of the confection does not need to be complete for other damage to occur to the frozen confection. Even if only the surface of the confection melts, on re-freezing it will tend to become coarse in texture due to the formation of large ice crystals. Such ice crystals are undesirable from an organoleptic standpoint.

A third problem would be attributable to moisture migration. Frozen desserts contain free moisture even at temperatures as low as -40°C/-40°F. Hard candies readily absorb moisture becoming progressively soft and sticky as their moisture content rises. It is unlikely that hard candy in direct contact with frozen dessert would remain hard for more than a few days during normal frozen storage conditions. At the same time, moisture lost from the frozen dessert would cause it to dry out. It is generally known in the art to provide barrier coatings or layers between an ice confection and a moisture absorbing coating, and if such barrier coatings are used to combat this problem, the manufacture of the product becomes more complicated.

Lastly, the high temperatures associated with manufacturing and handling hard candies at temperatures of 143°C/290°F or more in close proximity to low temperature frozen dessert would further introduce issues concerning safety and good manufacturing practices.

Alternatives sought to solve these problems have likewise failed to provide a solution. One such alternative entails, for instance: pre-forming the hard candy into a solid shell (by poring it into or over some form of molding device, and then leaving it to solidify and cooling prior to filling the cold shell with the frozen dessert mass. While this alternative would avoid the problem of melting of the frozen dessert when it comes in contact with the hot candy, it would not overcome the problem of moisture migration, as the latter would still require some type of moisture barrier (e.g., a fat based coating) to be provided between the hard candy and the frozen dessert. The addition of such a barrier complicates the manufacturing process and adds cost to the final product.

Several patents disclose fat-based coatings on ice cream or confections. For example, U.S. Patent No. 6,071,546 describes an ice confection comprising an ice confection core, a fat- based outer coating layer, and a precoating layer consisting essentially of an edible emulsifier located between the ice confection core and the edible fat-based outer coating layer. U.S. Patent No. 5,500,233 discloses a composition for improved adhering of a continuous coating to frozen fat-based confections wherein the composition includes a polysaccharide and a suitable carrier as an interface layer between a frozen fat-based confection and a coating. These patents require the addition of a barrier type coating which as noted complicates manufacture and adds cost.

Other patents disclose modified coating formulations. U.S. Patent No. 6,818,238 relates to an ice confection coated with a fat-based coating layer, in which the fat comprises a palm mid fraction with a melting point of about 26°C/80°F in an amount sufficient to reduce or prevent core bleed. U.S. Patent No. 5,273,763 discloses a fat-based coating for frozen confectionary products comprising a deaerated oil-in-water emulsion comprising, by weight of the emulsion, from 20% to 50% edible vegetable oil, from 1% to 10% flavor, an emulsifier, an artificial sweetener and water. U.S. Patent No. 5,876,774 relates to a method of solidification of a fat- based confection comprising the steps of adding an insoluble fiber and cooling. U.S. Patent No. 6,689,406 discloses a process and an apparatus for applying to confection or ice cream products whereby the coating dispensing devices move in a path along or between one or more rows of ice cream or confectionery products, thereby applying a patterned coating that is preferably reproducible. U.S. Patent No. 6,060,094 discloses a method for reducing the fat content in a fat- based confectionary coating material, wherein at least a portion of the fat-containing component of the coating material is replaced with a liquid medium chain triglyceride. None of these coatings, however, provide the texture and mouthfeel of a hard candy coating.

Accordingly, there remains a need for improved or novel combinations of hard candy and ice confections and these are now provided by the present invention.

SUMMARY OF THE INVENTION

It has now been discovered, surprisingly, that it is possible to develop a fat-based coating that may be applied to the frozen confection by dipping, enrobing or spraying/ showering that when set resembles a hard candy layer. The formulation of the coating is a key attribute to making it resemble hard candy, not only in terms of its texture, but also in terms of its flavor and appearance.

An important aspect of the current invention which determine the coating texture of the fat-based hard candy coating is the particle size of the ingredients, especially the sugars (or sugar substitutes), and their relative proportions. The present invention contemplates the use of a first sugar component or sugar substitute having a granulometry of at least 20 microns (for example, a 1Ox sugar), a second sugar component (for example, a granulated sugar) having a granulometry that is different than that of the first component by a granulometry factor of at least 8 to 20, and a fat component with a fat content of at least 33% w/w, where the first and second sugar components are present in relative amounts which provide a weight ratio sufficient to impart a hard candy texture and appearance to the coating. Advantageously, one sugar component can have a granulometry of between 30 and 40, and the other between 400 and 500 microns, respectively. The first and second sugar components are further respectively present in a preferred weight ratio of 2.5:1 to 1 :2.5. Generally, one sugar component is present in a greater amount than the other.

Whereas conventional frozen confection coatings use granulated sugar or 10x, they typically only use one of them. Furthermore, whereas conventional coatings most commonly utilize granulated sugar as a starting material, the large particle size of this sugar is finally refined to a particle size of 0.1- 30 microns. The present invention contemplates the use of both a first and a second sugar component, where neither of them is further refined, and where the combination of both imparts the qualities of coarseness and crunch. Thus, the sugar components provide less than 5% by weight of sugar components having a particle size that is less than 20 microns and often much less than that. Additionally, the use of a specific proportion of the first sugar component to the second sugar component serves to control the degree of coarseness to a desired level.

The fat component comprises coconut oil, palm kernel oil, non-lauric vegetable oil, palm oil, sunflower oil, peanut oil or fractions thereof, cocoa butter, milk fat, butter, or blends thereof and provides a fat content of at least 33% in the coating. In addition to sugars and/or other carbohydrates or sweeteners, and fat, other ingredients that may be used in hard candies, include, but are not limited to milk, lecithin, condensed milk, glycerin, salt, citric acid, sodium bicarbonate, a non-fat component such as non-fat milk solids or whey solids, inclusions (e.g. chopped nuts), nut pastes, colors and flavors. Generally, each component is provided in a dry state.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a novel fat-based coating formulation, which when applied to all or a portion of the outer surfaces of a frozen confection resembles a hard candy layer in terms of texture, flavor and appearance, and which seeks to avoid the problems in the prior art associated with the application of hard candy to a frozen confectionary, e.g., ice cream.

The present invention avoids the problems associated with coating a frozen dessert in real hard candy, such as: thermal damage of the frozen dessert by the hot candy; moisture absorption by the hard candy layer and drying out of the frozen dessert; the good manufacturing practice problems associated with the manufacturing and handling of hot hard candy (at temperatures of 143°C/290°F or more) and placing it in close proximity to a frozen confection. It further avoids problems associated with filling in frozen confections into pre-formed hard candy shells, such as increased complexity associated with manufacturing pre-formed hard candy shells and the need to apply a moisture barrier between the frozen dessert and the hard candy shell.

One important advantage of the coating in the ice confection of the present invention is that the overall quality of the ice cream product is dramatically improved. Fat-based coatings protect the surface of the frozen confection from drying out during storage and distribution. Other direct advantages are an improvement of the appearance of the product due to reduction or even elimination of cracking. Furthermore, the aesthetic appearance of the product is enhanced, particularly for children, allowing for flexibility in terms of flavor, color and general appearance appropriate for the market. The fat -based coating of the present invention resembles in texture, flavor and appearance crushed hard candy, and thus provides the test sensation of hard candy and an ice confection combined. Moreover, an additional benefit of the present invention is found in the ease of its use. Fat-based coatings are relatively easy to handle and use. They may be applied to frozen confections using conventional methods (dipping, enrobing or showering).

By ice confection is meant any aqueous based frozen product. Typically the ice confection has a sweet or semi-sweet taste. Examples of ice confections include, but are not limited to, ice cream, ice cream analogues, frozen yoghurt, sherbet, sorbet, ice milk, frozen custards, and water ices, i.e., aqueous solutions that are frozen. Ice confection products include, but not limited to, bulk products, novelties (e.g., bar and stick items), hard pack and soft serve specialties (e.g., molds, decorated items and slices), desserts, puddings, frosted items, frappes, punches, bisques, lactos, mellorenes, non-dairy items, and the like. The ice confection may contain optional ingredients such as, but not limited to: inclusions (e.g., fruit, nuts), chocolate, and flour based products. By ice cream analogue is meant a product similar in structure or function to an ice cream but which may not meet the legal definition(s) of ice cream in terms of its specific composition or process of manufacture. The invention is particularly suitable when the ice confection is ice cream. In the invention, the ice confection may be a portion, dome, bonbon, morsel, bar, stick bar. It can be extruded or molded.

For purposes of the present invention, hard candy may be defined as a low moisture confection made by means such as heating an aqueous solution of sugars, syrups (e.g. corn syrup) and/or polyols (in the case of sugar-free candies) to a temperature of typically 143-171° C (290-340 F) resulting in reduction of its moisture content to under 5%. Non-limiting examples of commercially manufactured hard candies include: toffee brittle, English toffee, peanut brittle, butterscotch, boiled sweets and peppermint candy.

The current invention is an alternative to using real hard candy on frozen desserts. It is a fat based coating that may be applied to the frozen confection by dipping, enrobing or spraying/showering that when set resembles a hard candy layer. The formulation of the coating is key to making it resemble hard candy, not only in terms of its texture but also its flavor and appearance. The following Table 1 lists preferred examples of ingredients that may be used to make the coatings. Other available substitutes are apparent to skilled artisans as being further appropriate for the purposes and the scope of the present invention. TABLE l .

The granulometry of the first and second sugar components is one of the defining aspects of the invention. Granulometry, as used herein, is a measure of particle size. Thus, in a preferred embodiment, the granulometry of one component is between 30 and 40 microns, and of the second component- between 400 and 500 microns. As noted, it is preferred that one sugar component be present in a greater amount than the other.

Determining factors for the coating texture of the fat-based hard candy coating are the particle size of the ingredients, especially the sugars (or sugar substitutes), and their relative proportions. The present invention contemplates the use of a first sugar component or substitute, such as, for example, 10x sugar, and a second sugar component, such as, for example, granulated sugar. As can be seen from Table 1 , the present invention contemplates the use of both granulated sugar and 10x sugar. Whereas conventional frozen confection coatings are usually refined to a mean particle size of 0.1 to 30 microns, in contrast refining or milling is not involved in the preparation of the recipes hereto described. The recipes are made simply by mixing all of the ingredients together where some of the ingredients are very coarse, typically in the above 100 microns range. In a preferred embodiment of the invention, granulated sugar is in the 400 to 500 microns range.

In one embodiment of the invention, the sugar components are present in a weight ratio of greater than 1 : 1 to 2.5 : 1. In a preferred embodiment, typical ranges for the first sugar or sugar substitute component are 20-40% by weight and for the second sugar component 10-20% by weight. In another embodiment of the invention the first sugar or sugar substitute component is 25-35% and the second sugar component is 12-18%. Whereas the relative ratio of the two sugar components controls the degree of coarseness, the presence of the two sugars with their higher granulometry than in prior art coatings are the primary factors that impart the qualities of coarseness, crunch and hard candy feel and organoleptic properties.

Particle size of ingredients other than sugar or sugar substitutes can have an important influence on other quality attributes, such as flavor. In one embodiment of the present invention, particle size of ingredients other than sugars or sugar substitutes is used to control taste. Large salt crystals represent points of high salt intensity that may be unpleasant for the taster. In a preferred embodiment of the invention, the salt used is either ground or milled.

In one embodiment of the invention, corn syrup solids, sweeteners or other similar substitutes are used to reduce overall sweetness. In a preferred embodiment where such a result is sought, 42DE corn syrup solids are used as they typically have only about 30% of the sweetening power of sucrose.

In another embodiment of the invention, sugars that increase the overall relative sweetness are used. In a preferred embodiment of the invention where such a result is sought, fructose, which has a relative sweetness of 180%, is used to increase the overall level of sweetness. In a most preferred embodiment of the invention, the fructose is used in the peanut brittle coating recipe.

In one embodiment of the invention, the fat-based hard candy coating has a reduced level of added sugar. This is achieved by replacing some of the added sugar with non-sugar bulking agents. As non limiting example, polyols, cereal flours such as wheat or corn, dextrin, cellulose, whey powder, fibers and combination thereof can be used as bulking agents. In a particular embodiment, the total amount of added sugar is below 50% by weight of the coating composition, preferably below 40%.

A number of fats may be used in the fat-based coatings of the present invention. Non- limiting examples include coconut oil, palm kernel oil, palm oil, sunflower oil, peanut oil and fractions thereof, cocoa butter, milk fat, non-lauric vegetable oils, e.g. partially hydrogenated soybean oil, butter, and other animal fats, vegetable oils, and blends thereof.

In one embodiment of the invention, a fat content in the range of 40-60% is used. In a preferred embodiment of the invention, the fat content is around 40%. In another embodiment of the invention, a reduced content of fats below 33% is used. This further results in the reduction of caloric value of the fat-based hard candy coating for frozen confections. In another embodiment of the invention, the fat or fats used do not contain trans fatty acids. In another embodiment, the fat used contains less than 50% saturated fat. One of skill in the art would be able to choose from a variety of flavors and colors to be used as ingredients in the present invention. In a preferred embodiment of the invention, the flavors and colors should be oil soluble or dispersed in oil.

In addition to the above ingredients, other ingredients that may be used in hard candies, include, but are not limited to: lecithin, condensed milk, glycerin, salt, citric acid, sodium bicarbonate, inclusions (e.g. chopped nuts and nut pastes).

The present invention is not limited to the particular materials mentioned above. Thus, other sweet tasting carbohydrates, sugar substitutes, fats, oils, colors, flavors, inclusions, or equivalents thereof, also fall within the scope of the present invention.

EXAMPLE 1

The following non-limiting Examples further illustrate the present invention. Parts are given by weight.

Butter Toffee Coating Recipe:

Process: In one embodiment of the invention, the dry ingredients were mixed a Hobart stainless steel bowl. Flavors and colors were added, where desired. The coatings were made without refining. The fats/ oils were then gradually added while mixing to avoid lump formation in a Hobart mixer set at speed number 1.

Coarseness of the ingredients affects at least two aspects of handling and application of the coating: sedimentation rates and blockage of spraying or showering nozzles. In one embodiment of the invention, improved means for preventing sedimentation and blockage are used. As a preferred embodiment, the invention contemplates paying special attention to stirring and providing a faster sedimentation rate, than used for a conventional coating, in order to prevent sedimentation. As another preferred embodiment, the present invention contemplates the use of an orifice size of the nozzle(s) that is sufficiently large, such as to avoid blockage by coarse particles in spraying or showering coating applications.

Following these steps, the formed product may be pumped directly to an agitated tank or other container. Alternatively, it may be stored in 20 kg pails, drums or other containers until ready for use. Following storage, thorough remixing of the contents in required.

EXAMPLE 2

Butter Toffee Coating Recipe:

NCA/CMA Casson Plastic Viscosity: 338 cps NCA/CMA Casson Yield Value: 5.2 dynes/cm²

Process:

(As in Example 1 )

EXAMPLE 3

Butterscotch Coating Recipe:

Process:

(As in Example 1 )

EXAMPLE 4

Peanut Brittle Coating Recipe:

Ingredient 1% Total |% Fat

Process:

(As in Example 1 )

EXAMPLE 5

Peanut Brittle Coating Recipe:

NCA/CMA Casson Plastic Viscosity: 338 cps NCA/CMA Casson Yield Value: 5.2 dynes/cm² (for Coating Without Nuts)

Process:

(As in Example 1 )

EXAMPLE 6

Red Peppermint Candy Coating Recipe:

Process:

(As in Example 1)

EXAMPLE 7

Red Peppermint Candy Coating Recipe:

Process:

(As in Example 1 )

EXAMPLE 8

"Caramel" Candy Coating

NCA/CMA Casson Plastic Viscosity: 338 cps NCA/CMA Casson Yield Value: 5.2 dynes/cm² Process:

(As in Example 1 )

The coating may conveniently be applied to the ice confection core by dipping, spraying or enrobing. The fat-based coating should be fiowable and coatable at the temperature at which it is applied which may be from 25° to 45⁰C. and more usually from 3O⁰C to 4O⁰C. If the temperature is too low, the coating may not flow and if the temperature is too high, e.g., 45⁰C, the coating may tend to slip off the ice cream without coating it properly and by causing excessive melting of the ice cream core.

EXAMPLE 9

Uncoated molded vanilla ice cream bars (2.5 fi. oz Crunch) from Dreyer's, Bakersfield, California were used for dipping in the lab. The uncoated bars typically weighed about 40 grams. Dipping was carried out with coating at approximately 33° C. Pick up weights per bar were typically 18-20 grams for all flavors. The coated bars consisted of approximately 31% to 33% coating. The relatively thick coating layer achieved was found to convey the best impression of a hard candy layer.

The present invention utilizes lower amounts of fat than conventional confectionery coatings. The examples illustrate typical values of around 40% fat and in general this amount would be in the range of 33 to 50%. Due to the granulometry of the sugar components, the present coatings behave like conventional coatings that contain 60% fat, despite reducing the fat content by at least about 15 to as much as 50%. The coatings thus provides health benefits regarding the lower fat content while not compromising on the taste and properties compared to conventional coatings. Also, non-fat milk or whey solids can be included for additional benefits, while the crunchy character of the present coating is a further organoleptic advantage.

Accordingly, the present invention also relates to the use of a first sugar component or sugar substitute having a granulometry of at least 20 microns, a second sugar component having a granulometry that is different than that of the first sugar component by a granulometry factor of at least 8 to 25, and a fat component for forming a confectionery coating having properties that are similar or identical to those of hard candy. These coatings have a fat content of at least 33%, and the first and second sugar components are present in relative amounts which provide a weight ratio sufficient to impart a hard candy texture and appearance to the coating.

Claims

THE CLAIMSWhat is claimed is:

1. A frozen ice confection product which comprises an ice confection and a coating at least partially covering the ice confection, the coating comprising a fat-based confection containing a first sugar component or sugar substitute having a granulometry of at least 20 microns, a second sugar component having a granulometry that is different than that of the first sugar component by a granulometry factor of at least 8 to 25, and a fat component, wherein the coating has a fat content of at least 33%, and the first and second sugar components are present in relative amounts which provide a weight ratio sufficient to impart a hard candy texture and appearance to the coating.

2. The product of claim 1 , wherein the first sugar component or sugar substitute has a granulometry of between 30 and 40 microns and the second component has a granulometry of between 400 and 500 microns.

3. The product of claim 2, wherein the factor is between 10 and 17, and the first and second sugar components are present in a weight ratio of between 2.5: 1 to 1:2.5.

4. The product of claim 3, wherein one sugar component or sugar substitute is present in an amount of about 20 to 40% by weight and the other sugar component is present in an amount of about 10 to 20% by weight.

5. The product of claim 4, wherein one sugar component or sugar substitute is present in an amount of about 25 to 35% by weight and the other sugar component is present in an amount of about 12 to 18% by weight.

6. The product of claim 4, wherein the first sugar component or sugar substitute is present in a higher amount than the second sugar component.

7. The product of claim 4, wherein the second sugar component is present in a higher amount than the first sugar component or sugar substitute.

8. The product of claim 1, wherein the fat component comprises coconut oil, palm kernel oil, non-lauric vegetable oil, palm oil, sunflower oil, peanut oil or fractions thereof, cocoa butter, milk fat, butter, or blends thereof and provides a fat content of at least 33% in the coating.

9. The product of claim 1, wherein the fat component includes at least a portion of non-trans fatty acids.

10. The product of claim 1, wherein the fat component includes less than 40% saturated fat.

11. The product of claim 1 , wherein the coating enrobes the ice confection.

12. The product of claim 1, wherein the coating includes milk or a non-fat component.

13. The product of claim 1 , wherein the coating includes a non-fat component of nonfat milk, whey powder or both.

14. The product of claim 1, wherein the coating further comprises one or more of a flavor, inclusions, or a color.

15. The product of claim 1, wherein the ice confection is an ice cream, ice cream analogue, frozen yogurt, sherbet, sorbet, ice milk, frozen custard, or water ice.

16. A process for producing a frozen ice confection product that includes a coating thereon which simulates that of hard candy, which comprises: formulating a coating comprising a fat-based confection containing a first sugar component or sugar substitute having a granulometry of at least 20 microns, a second sugar component having a granulometry that is different than that of the first sugar component by a granulometry factor of at least 8 to 25, and a fat component, wherein the coating has a fat content of at least 33%, and the first and second sugar components are present in relative amounts which provide a weight ratio sufficient to impart a hard candy texture and appearance to the coating; and applying the coating to at least partially cover an ice confection to produce the product.

17. The process of claim 16, wherein the coating is applied to the ice confection by dipping, spraying, enrobing or showering.

18. The use of a first sugar component or sugar substitute having a granulometry of at least 20 microns, a second sugar component having a granulometry that is different than that of the first sugar component by a granulometry factor of at least 8 to 25, and a fat component for forming a confectionery coating having properties that are similar or identical to those of hard candy, wherein the coating has a fat content of at least 33%, and the first and second sugar components are present in relative amounts which provide a weight ratio sufficient to impart a hard candy texture and appearance to the coating.