WO2006028360A1

WO2006028360A1 - Method for preparing cacao-beans for producing food products

Info

Publication number: WO2006028360A1
Application number: PCT/LT2005/000002
Authority: WO
Inventors: Steponas Kazimieras Dziugys; Algis Dziugys
Original assignee: Steponas Kazimieras Dziugys; Algis Dziugys
Priority date: 2004-09-06
Filing date: 2005-08-18
Publication date: 2006-03-16

Abstract

The inventive method related to the confectionery industry and can be used for confectionery, pharmaceutical and other sectors where cacao beans are used in the form of a raw material. Said method makes it possible to reliably sterilise shelled cacao beans. The aim of the invention is to give a new property to the cacao bean shell, i.e. brittleness and to use said cacao shell for food products. The inventive method also gives useful properties to the cacao beans, even insufficiently ripe or insufficiently fermented, thereby making it possible to avoid the loss of raw material and valuable substance and to give new properties to a novel product. The inventive method also makes it possible to produce chocolate and candy fillers, cacao powder from the powdered cacao shell and to add it into other food products. The inventive method consists in steaming roasted shelled cacao beans, in exposing them to air flow action at a temperature ranging from 80 to 170 °C and in treating said shelled cacao beans by an oil, preferably a cacao oil at a temperature of 120-170 °C. When necessary, the cacao beans are exposed to the action of a sugar substance solution at a temperature of 40-150 °C.

Description

METHOD FOR PREPARING COCOA BEANS FOR FOOD PRODUCTION

The method relates to the confectionery industry and can be intended for the confectionery, pharmaceutical and other industries where cocoa is used as a raw material. In the production of cocoa liquor, cocoa shell and sprout are separated from the cocoa kernel, after which the core is sent to further production processes, and cocoa shell and sprouts to industrial waste.

The quality of cocoa beans coming into production significantly affects the quality of confectionery: cocoa beans can be unripe or overripe - in both cases it negatively affects the quality of the product. Basically, the characteristic aroma of cocoa beans is achieved in two stages: 1) during fermentation of cocoa beans at the places of their cultivation; 2) during the heat treatment of cocoa beans (roasting) at the confectionery factories. Although well-fermented cocoa beans do not have an inherent aroma prior to heat treatment, there are components on which aroma depends. Unripe cocoa beans do not have enough Sugars, and they serve as one of the main substances for the action of enzymes during fermentation. Typically, in well-fermented cocoa beans, the basis of carbohydrates is glucose and fructose, sucrose - in an insignificant part and insufficiently fermented cocoa beans, sucrose prevails [Rahap T. A. "Gorsliap", 1969, 69, Nr. 1632. Rahap T. A. "Gorsliap", 1970, N. 1; four.].

To achieve good quality, ripened cocoa beans are immediately fermented and then dried to 5-6% moisture [Asmir Nagap. Sosa Beaps, with a cup of perfume, the quality of protein. Vuletip - Bali - Repalitiop - Medap. 1984. 15 (1) 19-30, 4, 3 ref.]. The meteorological conditions influence the quality of cocoa beans cultivation, therefore cocoa beans are insufficiently fermented - manufacturers eliminate this drawback.

In the process of fermentation, the content of volatile amino acids increases. A small amount of acid complements the aroma in chocolate, and a large concentration of them gives an unpleasant odor. Under good conditions, the amino acid composition of cocoa beans is formed at the end of fermentation and during the drying process [HoIm CS. Aston JW, Douglas K. The Effects of the Orgapis Asipos Cao on the flavour of scholate. Jourpaul of thе Sіepse оf Food apd Аgriсulture. 1993. 61 (1) 65 - 71, 19 ref.].

The component of cocoa beans and their quality depends on the area and soil where they are grown. For example, the small cocoa beans ,, Sulawesi "from Indonesia have cocoa butter in the range of 48-51%, while normal cocoa beans have 54% or more cocoa butter, such as cocoa beans from the Ivory Coast Bones (African) When the oil is less than 54%, the viscosity of the cocoa liquor increases, it is more difficult to eliminate the cocoa shell, its amount increases in the cocoa liquor, and this complicates the operation of the equipment.

In the food industry, various methods of sterilizing food products are known: direct or indirect heating or mixed [BOROWSKI, K.L .; AYRES, S. A. "Thermobasteriologu of UHT rssed foods". Development Methods of Food Microbiology (1982 1, 119 - 152 [En, 14 (ref.) Samrdep Food Reservatiop Res., Сyrpg Samrdep GL 55 6 LD. UK.].

The closest analogue is the method that is implemented in the BUHLLER SLS equipment. Here, unrefined cocoa beans are heated with steam at a pressure of 12-14 atm for 30-40 sec. Cocoa shell gains moisture from 11-13% to 30-35%, and the moisture of the cocoa core rises to 5-7%. The cocoa shell is heated from 20 ⁰ C to 130 ⁰ C, and the temperature of the cocoa kernel reaches 90 ⁰ C [BUHLLER SLS Kakao'Ohpep-Debakterisiеrпg Ссхематиссее Фрктиопс-Дарстеllшig]. After sterilization, the cocoa beans are dried, crushed, the cocoa shell is separated and sent to waste, and the cocoa kernels are sent to production.

The disadvantage of the existing technology is that cocoa shell after sterilization is not sufficiently processed and does not acquire the necessary properties for the production of products, so it is sent to waste. In addition, a steam of 12 to 14 atm pressure is required.

Roasting cocoa beans is one of the main operations that determine the formation of very necessary and valuable aromatic substances. Several methods are known for roasting cocoa beans: roasting whole, crushed cocoa beans, roasting cocoa liquor. In the process of heat treatment, there is a decrease in amino acids and reducing Sugars due to the sugar-amine reaction (Mayer reaction) with the formation of the aroma and taste inherent in chocolate [A.I. Dragilev, G.A. Marshalkin. Basics of confectionery production. Moscow "Kolok" 1999, p.195-200]. The best aromatic indicators are cocoa beans with a moisture content of 2.5%, which were fried at 134 ^° C. The determining indicator of this reaction is reducing sugar, the amount of which has decreased significantly after 45 minutes. from the beginning of the process [Reipiusius GA, Keeney PG, Weissberger W. Factors affecting the concentration of the substances and conditions // J. Agris, Food Chem. 1972. VoI / 20, p. 202]. To speed up the process of aroma formation, it is customary to moisten cocoa beans in production practice before drying and roasting.

In the above methods, when grinding cocoa beans, there is no separation of cocoa shells and cocoa kernels cannot be used as raw materials for food production. By the content of substances, cocoa shell and sprout are not inferior to cocoa beans:

[G.A. Marshalkin. Confectionery technology. Moscow. Food industry. 1978, c. 447, 143, 158].

In addition, when roasting cocoa beans, the transition of cocoa butter from the kernel to cocoa shell is in the range of 1-1.5%, ultimately, in cocoa shell cocoa butter increases from 3 to 4%. Cocoa shell makes up from 11 to 14% of the total mass of cocoa beans, a sprout - 0.9%, they cannot be crushed due to their high hardness and sterilized, so they are sent to waste [G.A. Marshalkin. Confectionery technology. Moscow. Food industry. 1978, p. 447, 157]. To reduce losses, cocoa beans are crushed into large particles, with a minimum proportion of small, but from this grinding and separation equipment is made more complex, the cleaning itself is complicated, equipment designs. At the same time, inevitably from 1.5 to 3.5 cocoa shells fall into cocoa nibs. This amount depends on the origin, grade, quality and grinding - separation equipment and other factors. Although the amount of cocoa shell and sprouts in the total ground mass is small, but because of their hardness they increase the wear of the equipment and reduce the quality of the chocolate.

It is known that cocoa shell is used in the production of sweets [Recipe for sweets and toffee. Food industry. 1986. p. 3246 128]. After cleaning and roasting during grinding, the cocoa shell is separated from the core, crushed into powder and added to the candy mass, where the cocoa shell is about 19% by weight of the candy. This product does not have the aroma characteristic of chocolate, but the most important thing is that it is not sterilized, very tough, difficult to grind and critically accepted by the consumer [G.A. Marshalkin. Confectionery technology. Moscow. Food industry. 1978, p. 447, 157].

Often, when the delivered cocoa beans have a moisture content of more than 7%, the drying and roasting time lengthens because of this, therefore, the productivity decreases, the taste and aroma of chocolate decreases. To speed up the process, roasting raises the temperature, which further reduces the quality of the chocolate.

In an effort to control the quality of the raw material deviation, in the manufacturing practice of chocolate it is customary to add fat or cocoa beans with a fat content of more than 54% during grinding of cocoa beans with reduced fat content. This practice is as the closest analogue of the invention.

This productive practice does not foresee the use of cocoa shells in the production of chocolate and other products. If a cocoa loaf is used in a particular production, then it is crushed and added to the candy mass.

The technology of the patented invention eliminates these disadvantages. The proposed method allows to reliably sterilize cocoa beans with cocoa shell. The aim of the present invention is to give cocoa shell a new property - fragility, as well as cocoa shell to use in the manufacture of food products. In addition, this technology allows you to give suitable properties and when the cocoa beans are not sufficiently ripened or not sufficiently fermented, this avoids the loss of raw materials and valuable substances or gives new properties to a new product. The fragile cocoa shell is crushed, like cocoa cake, from which can produce chocolate and candy fillings, cocoa powder, as well as add to other food products.

These problems are solved by the fact that the method of preparing cocoa beans for food production, which includes cleaning cocoa beans, sorting, sterilizing, drying, roasting and grinding them, is supplemented with new operations: after frying, cocoa beans with cocoa shells are steamed and exposed 80 -170 ⁰ With a stream of air, as well as cocoa beans with a cocoa shell, they process 120-170 ⁰ C with fat - best of all with cocoa butter.

In the proposed method, the novelty is that the treatment is performed with superheated steam under a pressure of at least 2.5 bar.

The proposed method is also characterized in that cocoa beans with cocoa shells are fried after frying with a solution of sugar substances at a temperature of 40-15O ⁰ C.

In addition, a distinctive novelty is the fact that amino acids, for example, soybean puree, are introduced into crushed cocoa beans with cocoa shell.

When a method of preparing cocoa beans for food production involves cleaning cocoa beans, sorting, sterilizing, heat-treating and separating cocoa beans from cocoa nibs, the novelty is that cocoa beans and cocoa beans that are separated are processed with fats 80-170 ⁰ C temperature and sent to further production processes.

The proposed technology provides an option where, after cleaning and sorting, the cocoa beans are exposed to 80 - 170 ⁰ C degrees of temperature fat.

One of the variants of the order of operations of the production method is shown in figure 1, and figure 2 shows the possible order of operations, when the cocoa shell is separated from the cocoa kernel for consumption in food products.

The figure 1 shows the sequence of operations of the production method, when the cocoa beans together with cocoa shells are used for the manufacture of food products.

The figure 2 shows the sequence of operations of the method, when the cocoa shell is separated from cocoa nibs and used in the manufacture of food products.

The figure 1 shows: pre-sorting and cleaning 1, cleaning and sorting before roasting 2, additional dry cleaning of cocoa beans 3, wet cleaning 4, drying - roasting 5, processing of cocoa beans with sugar solution 6, removing excess moisture from the surface of the cocoa beans 7, processing the shell of cocoa beans with fats 8, where one of the operations is performed: soaking by sinking the cocoa beans 8.1, or soaking by dipping 8.2, or soaking by spraying cocoa beans 8.3.

The following figure 1 shows: grinding cocoa beans into grains 9, production of cocoa liquor 10, indicator a shows the input of additional substances (fats, sugars, amino acids) in the grinding process 11, drying and roasting the crushed mass 12. Index b shows the input of additional substances when the cocoa mass is not additionally dried. The pointer d shows the direction of the cocoa shell separated from the cocoa nibs, processing in figure 2. The pointer e shows the case when the cocoa beans, after cleaning and sorting 2, are sent directly to the roasting machine 5. Cocoa shells can be separated and prepared for production at other production sites processes. Figure 2 shows the roasting of cocoa shells in fat 13, removal of excess fat 14, grinding of cocoa shells 15, removal of free fat 16, production of cocoa powder 17. Figure 2 shows two possibilities for processing cocoa shells. In the first case, the pointer d shows the direction of the cocoa shell, when the cocoa beans, after drying and roasting, are sent for grinding 9 (Fig. 1), and from there to operation 13.

In the second case, it is shown when cocoa beans with cocoa shell are processed from 1 operation to 9 (Fig. 1), after which the cocoa shell is sent to operation 15. Pointer f shows the case when the operation of removing excess fat from the mass of cocoa shell is not required, and it immediately sent to the production of powder 17.

The implementation of the method

When pre-sorting and cleaning 1 cocoa beans are cleaned of foreign solids, after which the cocoa beans are subjected to final cleaning by already known methods. Cocoa beans, if required, are sent to operation 3, where they carry out dry cleaning, and are sent, if required, to operation 4 of wet cleaning. Here, cocoa beans are washed with water 80-100 ⁰ C. From 7 to 12% of water is absorbed into the surface of cocoa beans. The amount of water depends on the quality of the cocoa beans (their size, initial moisture, etc.). After that, the cocoa beans are sent for drying-roasting 5, at a temperature of 80-170 ⁰ C. Raw cocoa beans cocoa shell has a fat content of 1 to 1.5%, but during the roasting process, fat is migrated from the kernel to the cocoa shell. From 1 to 1.5% fat is additionally absorbed in cocoa shell.

After roasting, the cocoa beans are sent to process 6, for processing with a sugar solution. In production it is not always necessary to introduce sugar, therefore, operation b is shown aside. Since sugar is introduced as a solution, there is excess moisture on the surface of the beans, so the cocoa beans are dried and the excess water is blown off the surface in step 7.

To avoid caramelization of sugar, processing is carried out at a temperature of a solution of 40 - 150 ⁰ C ₅ for example, a solution of reducing Sugars or sorbitol. Processing with sugars can improve the consumer qualities of cocoa beans and the fragility of cocoa shells, as well as increase the number of sugars in them.

Since sugars are introduced after processing the cocoa beans with a sugar solution, to remove water from their surface, the cocoa beans are blown with hot air 7, where its temperature is 70 - 110 ⁰ C.

When cocoa beans are not processed with a sugar solution, cocoa beans are moistened with steam, the pressure of which is above atmospheric pressure, to be sterilized and sprayed with fat, and they are dried with superheated steam or hot air. Heat treatment and sprinkling with fat of cocoa beans can be combined in one operation 7-8 or their order will change places depending on the regulations of the technological process.

If it is not necessary to process the cocoa beans with a sugar solution, in this case, after operation 5, they are sent to operation 7, which in this case can be combined with operation 8 (fat processing). If there is no water condensate on the surface of the cocoa beans, then the fat is absorbed according to the technological regulations. Removing the high humidity of cocoa beans from the sterilization process is performed when drying the cocoa beans with hot air or superheated steam when combining steps 7 and 8.

In an effort to give the consumer properties of cocoa shell and improve the properties of cocoa beans, they are processed with fats 8. The fat content of cocoa beans sent to operation 8 for processing with fats is from 2 to 3%. Cocoa beans are processed with fats, the temperature of which is 80-170 ⁰ C. Depending on the needs of fats in cocoa beans, fat is introduced into them in several ways. Cocoa beans are drowned in 8.1 fat or doused with 8.2 grease or sprinkled with 8.3 grease. The sequence of selecting the sequence of operations from 8.1 is a decreasing amount of fat in other operations under all other identical technological process conditions (temperature, holding time in fat, etc.). The best option depends on a predetermined fat content in cocoa shells. Cocoa beans are drowned when 8-24% cocoa shell is required, cocoa beans are doused when 5-15% is required, and sprinkled with fat when 3-12% is required. The method of processing fat is selected depending on the variety of cocoa beans, their ripeness, the quality of fermentation, the moisture content of cocoa beans. If there is a large microbiological contamination in cocoa beans and they are not treated with sugar solution, they are processed in fat up to 170 ⁰ C. Ultimately, the temperature is determined by microbiological contamination and the selection of the heat treatment method (drying, roasting), as well as the desired amount of fat in cocoa bean. It is better to treat cocoa beans with a stream of fat under pressure (pouring, sprinkling), from this the fat penetrates deeper into the cocoa shell and gains it 7-15%. For example, cocoa beans from Indonesia "Sulawesti GF", which are soaked in this operation at a temperature of 20 - 130 ⁰ C. At the end of the process, the fat content of cocoa shells increases from 2.5 to 14%, and thereby the fat content of cocoa beans increases from 49 up to 52%, which makes cocoa shell more fragile, which reduces the negative impact of cocoa bean abrasion on equipment.

Cocoa beans and their surface - cocoa shell after processing in fat with sufficient brittleness are sent to the crushing operation 9. After crushing, the cocoa nibs along with the cocoa shell are sent to the production of cocoa liquor in operation 10.

If the quality of cocoa beans is unsatisfactory, additional operations are provided for in the technological process: additional input of amino acids, fats and sugar solution H ₅ and also drying of cocoa nibs 12. For this, two cases of input of amino acids and sugar solution are provided. In case a, the amino acids and sugar solution are introduced into cocoa nibs in step 11, after which, in step 12, they are dried and sent to the production of cocoa liquor in step 10. In case b, amino acids and sugar solution are introduced into cocoa nibs in operation 11, after which they are directed to the production of cocoa liquor 10. In the production of cocoa liquor, its temperature is from 105 to 145 ⁰ C, as a result of which water evaporates from it and therefore operation 12 disappears. The introduction of an additional amount of fat (cocoa butter) in this operation depends on the quality indicators of cocoa beans, the properties of the equipment and the final requirements for the properties of cocoa liquor. When the fat content of cocoa beans is sufficient, cocoa butter is not added. If the fat content of the cocoa beans is not sufficient, you can mix two varieties of cocoa beans, one of which has a sufficiently high fat content or add fat in step 11. In the manufacture of cocoa liquor, the fat content should be 54-55%. So from cocoa beans with cocoa shell cooked cocoa liquor can be used in the manufacture of chocolate.

In some cocoa beans, due to the insufficient content of free amino acids or reducing Sugars, especially glucose and fructose, the sugar-amine reaction, the so-called Mayar reaction, does not fully develop, because of which there is not enough manifestation of aromas and flavors, amino acids are introduced for this purpose and sugar solution or one of them:

1. In the production of cocoa liquor, operation 10, when its temperature is 105 -145 ⁰ C, a sugar solution is introduced, which binds volatile substances, reduces their evaporation.

2. Introduce into the cocoa nibs, operation 11, a solution of reduced sugar, after which the nibs are dried to 1.5-2.5% moisture and then cocoa liquor is produced from it.

When there are not enough amino acids in cocoa beans, amino acids, for example, soya puree, are introduced into the crushed mass, because their composition is closest to cocoa beans.

When the fermentation quality of the cocoa beans satisfies the technological requirements, then fat is added to the cocoa nibs with cocoa shell in step 11, and then the technological process is carried out along arrow b.

When the fermentation quality of the cocoa beans does not satisfy the technological requirements, and the fat content of the cocoa beans is more than 53%, then amino acids, for example, soya puree, sugar solution or one of these components, and the subsequent production process are carried out in directions a or b during process 11 . When the quality of the cocoa beans meets the technological requirements, cocoa shell can be processed by a simplified process. The method can be used by interchanging the operations of the method and the modes of the process itself. The best option is determined depending on the quality of the cocoa beans and the requirements of the properties of the new product.

Example 1

After sorting and dry cleaning, i.e. after 1, 2, 3 operations, cocoa beans are washed with water 80-100 ⁰ C in operation 4. Here the cocoa shell collects about 30% of the moisture that accumulates in the surface of cocoa beans, where the total moisture is 5 - 7%. After that, the cocoa beans are soaked in sugar solution 6, the temperature of which is 90 - 145 ⁰ C, and in order to increase the diffusion of Sugars into the cocoa shell, excess moisture is removed from the surface of the beans using a stream of hot air 7, the temperature of which is 80 - 140 ⁰ C and further cocoa beans doused with fats 120 - 170 ⁰ C temperature 8.2. Cocoa shell absorbs about 9-14% of fat. Next, the frying operation 5 is performed at a temperature of from 80 to 170 ⁰ C, after which the cocoa beans are crushed into grains 9. Cocoa shells and cocoa beans are used for the production of chocolate or cocoa shells can be separated for other industries. Next, cocoa liquor 10 is produced, according to the technological regulations.

In addition, when performing the above operations, the biological contamination of cocoa beans is reduced - i.e. sterilization process. So, for example, when the initial contamination of cocoa beans was 260,000 cfu / g, after operations 4, 6 and 7, the total number of bacteria was 177,000 cfu / g, and after treatment with fats it decreased to 9600 cfu / g, ultimately, after drying, roasting 5 reaches 3300 cfu / g.

The most effective sterilization process is achieved by performing a shortened process in the following sequence of operations: 1-2-3-5-6-8, i.e. after sorting-cleaning-roasting, as well as treatment with water, steam and fat, when the initial microbiological parameters were: the total number of bacteria was 3,000,000 cfu / g, and enterobacteria, coliform bacteria Escherichia coli, yeast and mold more than 1,100 cfu . So in the end result, the total number of bacteria decreases less than 100 cfu / g, Epterobasteriaseae, coliform arteries, Escherichia coli - all less than 0.30 cfu / g, yeast and mold less than 10 cfu / g.

The effect of reducing the total number of bacteria was ⁴ times in Zl About ⁴ times, and the process also guarantees sterilization of Sahopella spr, when it is present in the feed.

Example 2

When using beans whose quality meets the technological requirements, for example, Gvoru Soast, but not sufficiently reducing sugar, the method is carried out in the following order: cocoa beans are sorted and cleaned 1, 2, additional dry cleaning is carried out 3, for example, with mechanical brushes, washed 4, treated with sugar solution 6, after which excess moisture is removed from the surface of the cocoa beans 7, after which the cocoa beans are dried and roasted 5. After frying, fat 8 is added to the hot cocoa beans and the cocoa beans are sent to the production of cocoa liquor 9- 10. For the further development of the aroma of cocoa liquor, it is advisable to process it in an adapted lipstick machine [A.I. Dragilev, G.A. Marshalkin. Basics of confectionery production. Moscow "Kolok" 1999, p.112-114]. The device consists of a hollow auger, to the surface of which coils are attached in the form of steel gear strips forming a four-auger auger. An agent circulates in the cavity of the screw, which maintains the desired temperature of the treated mass. The screw is mounted in a three-section housing, inside of which fingers are also spirally located, between which there are serrated strips of turns of the screw. When the toothed auger with cocoa liquor is rotated into the hollows, it repeatedly hits the motionless fingers, while intensive churning-aeration of the mass and washing with air occurs. The air moves against the movement of the cocoa mass. The air temperature is from 70 to ^{0 °} C. Thus, the sugar-amine reaction occurs (Mayar reaction). This improves the taste and aroma of cocoa liquor, such as, for example, significantly reduced ether and butanol, volatile acids, furfural, etc. When the quality of cocoa liquor meets the requirements, it is directed to the production of products.

Depending on the requirement for productivity and quality, the installation can be used in the sequential doubling of such machines.

If commercial cocoa beans have a moisture content of less than 4%, then after cleaning 1, cleaning-sorting 2, they are fried in fat from 120 to 170 ⁰ C, to moisture 2.5%. At at this temperature, the cocoa beans are sterilized. Then they are crushed to the grains, add fat and other additives and processed in the described modes. If required, cocoa nibs are still sterilized in operations 10 or 12.

When the process requires repeated heat treatment of cocoa nibs and cocoa liquor, in order to avoid undesirable effects on the aroma, cocoa beans are fried only once above 100 ⁰ C, and other thermal effects are short-term - less than 3 minutes. or lower frying temperature.

If the process does not guarantee the sterilization of cocoa beans, then BUHLER SLS equipment can be used. Then the cocoa beans are sent to operation 5 through sterilizing equipment. All processes are performed in the above modes.

The essence of this invention is also the use of cocoa shells for the preparation of cocoa beans for food production, which is separated from cocoa nibs, which is processed in two ways:

The first way.

Cocoa beans are processed from 1 to 9 operations (Fig.l) according to the proposed order and description. After heat treatment, the cocoa shell has a fat content of 2 to 3%, in step 8, the cocoa shell absorbs another 6 to 12% fat, which makes the final fat content of the cocoa shell 8 to 15%. For the manufacture of cocoa powder, such a fat content is sufficient. If, after grinding in step 9, the separated cocoa shell satisfies these conditions, it is sent to grinding 15 (FIG. 2, d) and then to the production of cocoa powder 17 (FIG. 2, f). When cocoa shell after operation 9 with fat content in the range of 8-15% is sent to operation 13, where they are treated with fat at a temperature of 80 to 170 ⁰ C, after which cocoa shell collects fat in the range of 8 to 24% and the total proportion of fat in cocoa shell increases in the range of 16-39%. Excess fat accumulates on the surface of the cocoa shell, in which case the cocoa shell is sent to reduce fat in process 14, for example in a centrifuge. Next, the cocoa shell is ground in operation 15 to the mass of the desired consistency, which depends on the amount of fat in it, grinding and recipe requirement. The prepared mass from cocoa shells is directed to the production of products, for example, fillings for sweets or chocolate, for glaze, biscuits, sweets and the like. If from the mass of cocoa shells it is envisaged to produce cocoa powder for drinks or other products, in this case, in operation 16, excess fat is squeezed out of the mass to 9-12%, after which the cake is sent to the production of cocoa powder in operation 17. The produced powder can be used for drinks or foods.

Second way

Cocoa beans are cleaned 1, sorted 2, dry cleaned 3 and wet cleaned 4 to 5 operations, where after frying the cocoa beans are sent to grinding 9 and the separation of cocoa shells (arrow d, Fig.l and figure 2). The separated cocoa shell containing from 2 to 3% fat is sent for frying in fat, operation 13, for example cocoa butter, at a temperature of 100 - 170 ⁰ C with an exposure in frying from 1 to 30 minutes. Here, cocoa shell is gaining additional from 8 to 24% fat in the chapel, from which the total proportion of fat is from 10 to 27%. Next, the cocoa is sent to further production.

Examples of the application of the method.

The components of the product are selected depending on the purpose of the product, at the request of consumers and the recommendations of health professionals.

Example 1

Cocoa beans, after roasting with a moisture content of about 2%, are served for cooking in cocoa butter at a temperature of ⁰ C, where they are boiled for about 30 seconds. After that, the cocoa beans are boiled in fructose-sorbitol syrup for about 2 minutes. Next, the surface of the cocoa beans is covered by gradually building up a mixture of soy and skim milk powder and fructose. The binding material for building is sorbitol syrup. After building, the weight of the new product increases by 38-45%. Such a product can be recommended for diabetics.

Example 2

Cocoa beans after sorting-cleaning 1-4 are boiled in cocoa butter for 10 to 40 seconds. at a temperature of about 105-135 ⁰ C. After that, cocoa beans absorb about 10% fat. Then boil in fructose-sorbitol syrup for about 2 to 15 minutes, where their weight increases from 6 to 20%. So cooked cocoa beans are ground together with grated mass of almonds, with pre-ground cocoa shell, as well as a mixture of powder from soy and fructose, after which they are molded into a layer of 1-6 mm and dried at 105 - 120 ⁰ C to a moisture content of less than 9%. If necessary, add flavors and molded candy shells. Then glaze or sprinkle with fructose-sorbitol powder. The product is suitable for dietary and diabetic nutrition.

Product Components:

Cocoa Beans 10-55%

Fructose-sorbitol syrup 5-20%

Almonds 0-20%

Cocoaella 2-18%

Soybean Powder 0-25%

Fructose 10-11%

Fat 0-15%

Flavoring about 0.14%

Lecithin about 0.05%

Example 3 Component Product:

Fructose 5-30% Lactose 0-25%

Skim milk powder 0-20%

Sorbitol 10-50%

Palm oil 5-25%

Cocoa shell and cocoa powder 2-15%

Ground waffles 0-15%

Akopol Fat SBR - 4 8 - 10%

Lecithin about 0.04%

Flavoring about 0.14%

Edible salt up to 0.02%

Citric acid 0-0.02%

Comment. When sorbitol in the formulation is more than 15%, the moisture content of the candies should be no more than 2%.

The components are mixed and crushed in a five-roll mill, then the crushed mass is given the desired plasticity by mixing it and adding the above amount of fat, as well as flavorings and lecithin. After reaching the mass of the required homogeneity from harnesses form it, they are cut and coated with glaze or sprinkled with sorbitol-fructose powder. Such a product is suitable for diabetic nutrition.

Example 4

This example may be suitable for cocoa beans when there are a lot of unripe and poorly fermented beans in them. Such cocoa beans are processed according to the proposed method from 1 to 4 operations, after which they are dried - fry in operation 5 to a residual moisture of 3-4%, then cocoa beans are crushed into cocoa nibs, without separating cocoa beans, trying to get more large cocoa nibs. After that, the grains are sent for cooking in syrup from dextrose and glucose, the cooking time is 10 seconds, the concentration of the syrup is 40-60%. After cooking, the total sugar content in cocoa nibs is 5%, including reducing sugar -4%. Next, the cocoa nibs are boiled in cocoa butter at a temperature of 120-125 ⁰ C to a residual moisture of 2.5%, after which it can be used for fillings of sweets and chocolate, as well as other products or directed to the production of cocoa liquor. When tasting cocoa shell, the inherent smell of fried cocoa beans, good, pleasant taste, good fragility, it is crispy, chews easily.

Example 5

Giving cocoa shell consumer properties, cocoa beans are processed according to the proposed method from 1 operation to 4 operations, after frying 5 cocoa beans are boiled in dextrose-glucose syrup, the concentration of which is 50%, the cooking time is 8 seconds. After that, the moisture content of the cocoa beans is about 6%, then the cocoa beans are boiled in cocoa butter at a temperature of 120-125 ⁰ C to a residual moisture of 2.5%. After processing, the microhardness of the cocoa shell decreases in the range of 86–110 MPa to 55–72 MPa. When testing, the cocoa shell had good fragility, was crispy, chewed easily, had a slightly sweet taste.

Example 6

Giving cocoa beans consumer properties, cocoa beans are processed in the same order as in example 5, but after frying they are soaked in water at 100 ⁰ C or steam is treated with water for 1-2 seconds until the surface of the cocoa beans reaches 7-15% moisture. Then they are boiled in cocoa butter to a residual moisture content of 2.5%.

When tested, the cocoa shell had good brittleness, was crispy and chewed easily.

Claims

Claim

1. A method of preparing cocoa beans for food production, consisting of cleaning, sorting, sterilization, drying - roasting and grinding, characterized in that the cocoa beans with cocoa shell after frying are steamed at a temperature of 80-170 ⁰ C and blown with an air stream , the temperature of which is 80 - 170 ⁰ C, after which cocoa beans with cocoa shell are treated with fat at a temperature of 120 - 170 ⁰ C.

2. The method according to paragraph 1, with the exception that steam treatment is performed under a pressure of at least 2.5 atm.

3. The method according to points II and 2, characterized in that the drying of cocoa beans is carried out at a pressure exceeding atmospheric pressure.

4. The method according to paragraphs 1-3, characterized in that cocoa butter is used to treat cocoa beans as fat.

5. The method according to paragraphs 1-4, characterized in that after roasting, cocoa beans with cocoa shells are treated with a sugar solution at a temperature of 40-150 ⁰ C.

6. The method according to paragraph 5, characterized in that amine acids are introduced into the crushed cocoa beans.

7. The method according to paragraph 5, characterized in that soy puree is used as the amino acid.

8. The method of preparation of cocoa beans for food production, consisting of cleaning and sorting, characterized in that the cocoa beans are treated with fat at a temperature of 120-170 ⁰ C.

9. A method of preparing cocoa beans for food production, consisting of cleaning, sorting, sterilizing, drying - roasting, grinding and separating cocoa shells, so that the separated cocoa shells are treated with fat at a temperature 120 - 170 ⁰ C and sent to further production processes.