Lecture 3 - Principles and processing of Confectionery-2.pdf

Raw Materials, Principles & Processing of Sugar Confectionery Lecture 03 Raw Materials and Ingredients Used in Sugar Confectionery Raw materials and different ingredients used in sugar confectionery are: sucrose and its derivatives, glucose syrups, other sugars,...

Raw Materials, Principles & Processing of Sugar Confectionery Lecture 03 Raw Materials and Ingredients Used in Sugar Confectionery Raw materials and different ingredients used in sugar confectionery are: sucrose and its derivatives, glucose syrups, other sugars, other sweeteners, fats, milk products, foaming agents, gelling agents, thickeners and stabilizers, emulsifiers, colours, flavours, acids, nuts and some processing aids.  Sucrose and its derivatives, sugar syrups, honey, intense sweeteners, bulk sweeteners – already discussed. Fats Fats for confectionery use must be completely or almost completely melted at about 37oC. If they have higher melting point they give an unpleasant greasy sensation in mouth. On the other hand, low melting fats lack body and tend to make sweets oily, which can also result in bloom defect on chocolate covered products.  Cocoa butter has almost ideal properties for use in confectionery. Lauric fats such as palm kernel and coconut oils, partially hydrogenated oils such as soy, ground nut, rapeseed, etc. are also used. Butter is used mainly for its flavour. Emulsifiers Emulsifiers used in confectionery are lecithin or glycerol monostearate. Both are used to assist the emulsification of fat into product. Lecithin is generally used for hard boiled sweets Glycerol monostearate is preferred for toffees and caramels as it provides lubrication for cutting knives during processing. Milk products Milk products such as spray dried milk powder, sweetened condensed milk, sweetened condensed skimmed milk, whey powder, sweetened condensed whey, etc. are used for their nutritive value, flavour and sometimes colour generated due to Maillard browning and caramelization. Gelling agents, thickeners and stabilizers These substances are mainly used for binding water and gives strength to the confectionery products. Gelatin, starch and modified starches, pectin, gum arabic, guar gum, locust bean gum, xanthan gum, alginates, etc. are commonly used. Colours Most confectionery products are not naturally coloured. Hence, colours are added to assist in flavour perception and to provide a means of differentiation between sweets in an assortment of flavours. Natural colours such as caramel and permitted artificial colours are commonly used in confectionery. Flavours Natural flavours, essential oils, and artificial flavours are used in confectionery applications. All flavours are to a greater or lesser extent volatile and in confectionery applications they are often added at high temperatures. Principles & Processing of Sugar Confectionery  A wide variety of products by varying: - ingredients used - To of boiling - Methods of shaping etc. In all cases, principle of production remains same:  Balance the recipe Prepare the ingredients Mix ingredients together Boil the mixture until the desired To is reached Cool Shape Pack Factors affecting: Many factors affecting the production & storage of sweets: The degree of sucrose inversion Time & To of boiling Residual moisture content in the confectionery Addition of other ingredients (eg. Fats, Milk powder)  Inversion of sucrose Sweets containing high concentrations of sugar (sucrose) may crystallized during manufacture or storage (commonly referred to as graining) Even this is desirable for certain products (fondants & fudge) in most cases considered as a quality defect.  Invert sugar (fructose & glucose) present in sucrose solution helps to control sugar crystallization A mixture of invert sugar & sucrose is more soluble than sucrose alone, & thus less easily crystallized.  When a sugar solution is heated, a certain % of sucrose breaks down to form “invert sugars”. This invert sugar inhibits sucrose crystallization & increase the overall concentration of sugars in the mixture. As a way of facilitating the amount of inversion, certain ingredients, such as cream of tartar or citric acid, may be used. Such ingredients accelerate the breakdown of sucrose into invert sugar & thereby increase the overall percentage of invert sugar in the solution.  Amount of invert sugar in the sweet must be controlled. Too much - make the sweet prone to take up water from the air & become sticky. Too little - insufficient to prevent crystallization of the sucrose. About 10-15% of invert sugar is the amount required to give a non-crystalline product. Time & To of boiling To of boiling is very important, as it directly affects the final sugar concentration & MC of the sweet. For a fixed concentration of sugar, a mixture will boil at a specific To. These are given in the following table:  Boiling point of sucrose solutions Sucrose conc. % Boiling point oC Boiling point oF 40 101.4 214.5 50 102 215.5 60 103 217.5 70 105.5 222 75 108 227 80 111 232 85 116 241 90 122 252 95 130 266  Variations in boiling To can make a difference between a sticky, cloudy sweet or a dry, clear sweet. An accurate way of measuring the temperature is to use a sugar or confectionery thermometer Other tests can be used to assess the To – cold water test To are known by distinctive names (soft ball, hard ball..) all of which are referred to the consistency of the product.  Type of sweet Temperature range for boiling (oC) Fondants 116-121 Fudge 116 Caramels & regular 118-132 toffee Hard toffee 146-154 Hard boiled sweets 149-166  Moisture content Water left in the sweet will influence its storage behavior & determine whether the product will dry out or pick up moisture. For sweets with more than 4% moisture, it is likely that sucrose will crystallize on storage. The surface of the sweet will absorb water, the sucrose solution will be subsequently weaken & crystallization will occur at the surface, later spreading through out the sweet.  Added ingredients Addition of certain ingredients can affect the To of boiling. Eg. If liquid milk is used in the production of toffees, the moisture content of mixture immediately increases. Therefore, require a longer boiling time in order to reach the desired MC  Added ingredients also have an effect on the shelf life of the sweet. Toffee, caramels & fudges which contain milk solids & fat, have a higher viscosity, which controls crystallization. On the other hand, the use of fats may cause the sweets prone to rancidity, & consequently the shelf life will be shortened.  Processing of confectionery items Table below outlines the processing stages for a selected range of confectionery items: Mix boil cool beat Form/Set ingredients Hard-boiled sweets * * * * fondants * * * * * Fudge * * * * * Toffees/caramels * * * * Jellies * * * * Processing  Boiling 3 main ways of boiling the sugar solutions: 1. simple open boiling pan 2. steam jacketed pan 3. vacuum cooker Steam jacketed pans are often fitted with scrapers & blades which make the mixing & heating process more uniform & lessen the possibility of localized over heating. Vacuum cookers are generally used at large scale.  Cooling All sweets are cooled slightly before being shaped. Most simply, the boiled mass is poured onto a table (made from metal, stone or marble to cool the product uniformly). The table should be clean & free from cracks, as they may harbor dirt & m.o. It is important that the boiled mass is cooled sufficiently, since if it is to be formed by hand there is a danger that the operator may suffers burns.  Beating Beating is a process which controls the process of crystallization & produces crystals of a small size. Eg. In production of fudge, the mass is poured on to the table, left to cool & then beaten with wood or metal beater Forming / Setting 2 main ways of forming sweets: 1. cutting in to pieces 2. setting in to moulds Moulds may be as simple as a greased & lined tray. Other moulds can be made from rubber, plastic, metal, starch or wood. It is possible to make starch moulds by preparing a tray of corn starch, not packed too tightly. Impressions are then made in the starch using wooden shapes. The mixture is poured into the impressions & allowed to set.  Packaging When sweets are stored without proper packaging, specially in areas of high humidity, sucrose may crystallize, making the sweet sticky & grainy. Individual wraps can be made from waxed paper, aluminum foil & cellulose film or a combination of these. In most cases, the sweets will be wrapped by hand. But for higher production, semi-automatic wrapping machines are available.  For future protection, the individually wrapped sweets may be packed in a heat- sealed polythene bag. Sweets can also be packed in glass jars or tins with close fitting lids. Classification of Confectionery Confectionery can be classified into four major groups. Sugar confectionery - products using mainly sugar such as boiled sweets, fondants, fudge, jellies, toffees, etc. Chocolate confectionery - cocoa, chocolate and chocolate products. Sugar confectionery coated with chocolate is also included in it. Flour confectionery - baked products such as cakes, biscuits, cream rolls, etc. Milk-based confectionery - milk-based sweets such as burfi, peda, rasogolla etc.