Specialty Fats In Food Industries

Chocolate,Bakery & Ice Cream28th Septamber 2014, Ahmed Abdel Moniem

1. Who we are

2. Specialty Fats for Chocolate

3. Specialty Fats for Bakery

4. Specialty Fats for Ice Cream

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Outlines

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IOI Group’s controlled integrated supply chain

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• The largest vegetable oil based Asian oleochemical manufacturer

• Combined refining capacity > 750,000 MT

• Global distribution

• 250.000 hectares

• 14 mills with >4 million MT capacity. 12 RSPO certified

• Enhanced agronomy R&D and yield management.

Plantations Oleochemical

• RM 4.1 billion revenue

• Listed on Bursa Malaysia stock market

• 30.000 employees

IOI Group

• Specialist & leading player in tropical oils

• Expert in commodities and specialties

• 3 million MT refining capacity

IOI Loders Croklaan

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Expertise built on rich experience

Achievements and Milestones

o Established in 1890 (UK)

o Invented CBE’s and OPO

o Leading the trans fat elimination

o CO-Founded the RSPO

o Regional Creative Studios

Expertise built on rich experience

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Positioned for your success

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Production location

Sales / Regional office

Bulk oil terminal

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Annual turnover > €1 billion

6 production locations / 9 sales offices

3mm MT of refining capacity / Over 1,000 employees

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At home in all segments

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Confectionery

Bakery Spreads CulinaryInfant

NutritionNon

FoodsFrying Dairy

Specialty Fats for Chocolate

Specialty Fats Definition

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Special Applications

Required

Specific physical properties

Bar moulded & shell moulded

Kinder Surprise (Ferrero) – The Smart Egg

After Eight (Nestle)

Mint fondant enrobed in dark chocolate The invertase ingredient

Mild chocolate treat with surprise toy

Exterior : Milk chocolate Interior : White chocolate

Hollow figures & sugar filled centres

Various enrobed products

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common chocolate application

various chocolate coated centres : biscuits, cakes, wafers etc.

could be premium or economic products

Aerated chocolates

Aero (Nestle) Bubbly (Cadbury) Airs (Lotte)

Bubble centre filled into moulded shell Subject to licking roller before back casing Higher fat content (> 38%)

Micro-aerated chocolate coating

Aeration level of 10% or more Improvement in taste Coating layer thicker and more Impression of chocolate

Chocolate

Air

Pressure releaseBubble expand

Holding tank Temper machine Enrobing machine

Chocolate-coated Candy Bars

Panned chocolate

Preglazing To seal nut surface to prevent transfer of nut oil

Chocolate coating Dark or milk chocolate can be used Cold air, ~15 oC, < 50% RH Pan revolving 18 – 22 rpm Hand panning, spray panning

Finishing glaze Syrup glaze, edible shellac glaze Chocolate has to set completely before finishing glaze

Chocolate Vermicelli

Cool air

Vermicelli

Conveyer

Drilled plate

Rotatingblade

Manufacture of chocolatevermicelli

Decoration use in flour confectionery

Extrusion through a perforated plate (with recessed holes)

When using pure chocolate, cooling is required to prevent friction heat from destroying the temper

Vermicelli is then transferred to panning machine

Glazed with syrup and colour may be addedRecessed

holes

Cocoa Butter Alternatives

Loders Croklaan

COBERINETM

CREAMELTTM

COUVATM

CLSPTM

555/eParhi 100KERME

BISCUITINETM

MARFATCARABUTABOS

FRYING OILSHORTENING

PALM FRACTIONSDURKEXTM

REVELTM

Product Range

Cocoa Butter Equivalent (CBE)

Based on non-lauric oilsOnly six base fats are permitted – Palm Oil, Illipe, Sal, Shea, Kokum and Mango Kernel

Rich in symmetrical triglycerides of the type POP, POSt, StOSt

Miscible in any proportion with cocoa butterCompatible physical properties with cocoa butterObtained only by refining and fractionation

Melting Profiles of CBE

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67

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20

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10

20

30

40

50

60

70

80

20 25 30 35 40

Temperature, ºC

% S

olid

s b

y N

MR

Cocoa Butter

Coberine 608

Coberine 901

Cocoa Butter Replacer (CBR)

Based on non-lauric oils (HPO)Usually fractionated and frequently hydrogenated

(COUVATM Hydrogenated Palm Olein)Under the proposed EU Directive (2000/36/EC) CBRs

could not be included in a product called chocolateA non-tempering fatCompatible at 20% with cocoa butter and butter fat

(Allow usage of cocoa mass in recipe)Correctly balanced recipe Product with excellent

mouldability, good melt, snap and contraction

Cocoa Butter Substitute (CBS)

Based on lauric oils (Palm Kernel Oil)Sometimes fractionated and frequently hydrogenated

Under the proposed EU Directive (2000/36/EC) CBSs could not be included in a product called chocolate

A non-tempering fatCompatible at a max of 5% with cocoa butter. Correctly balanced recipe Product with excellent mouldability, excellent melt, snap and contraction

Compound Chocolate Based on CLSPTM

Dark Type Compound 14% Cocoa Powder

32% CLSPTM

7% Skimmed Milk Powder

47% Sugar

Additives:Lecithin/flavour

Milk Type Compound6% Cocoa Powder

32% CLSPTM

17% Skimmed Milk Powder

45% Sugar

Additives:Lecithin / Flavour

Specialty Fats for Bakery

Bakery Shortening

Product Name TFA % Solid by NMR, typical value

20 oC 25 oC 30 oC 35 oC 40 oC

Shortfat 370 < 1 28 17 11 6 5

Shortfat 420 < 1 35 23 15 11 7

Shortfat 460 < 1 45 32 22 15 10

Shortfat 480 < 1 48 36 26 20 14

Eating Quality• Better Aeration/creaming properties• Improved volume• Handling ease• Good Stability• All purpose shortening from MP 33-54oC

Bakery Margarine

Product Name TFA % Solid by NMR, typical value

20oC 25oC 30oC 35oC 40oC

Marfat 060 < 1 33 23 16 10 4

80% fat and 16% water (water in oil emulsion) A substitute for butter Industrial margarine functionality Wide plastic range with good creaming properties

Industrial Frying

Texture Fried Food Flavour Mouthfeel AfterTaste

ROLE OF OIL & FAT IN FRYING

Conceptual heat and mass transferduring frying

Selection of Frying Oil

Product Name TFA % Solid by NMR, typical value

20 oC 25 oC 30 oC 35 oC 40 oC

DurkexTM 200 < 1 1 0 0 0 0

Palm Olein IV 56 < 1 5 0 0 0 0

Palm Oil < 1 28 15 10 7 4

Milk Fat ReplacersProduct Name TFA % Solid by NMR, typical value

20 oC 25 oC 30 oC 35 oC 40 oC

BOS 6262 < 1 29 17 11 6 4

BOS 7534 6 30 21 15 8 0

CarabutaTM NH < 1 50 28 16 10 6

CARABUTA TF contains essential flavor precursors of milk fat.

During cooking, the butter flavorin CARABUTA TF develops in exactly the same way as it does whenmilk fat itself is used.

Sugar Confectionery

Fat functions as flavor carrier Fat acts as lubricant and softener (less sticky product)

Hard candy (low moisture) Lauric Soft caramel / toffee (higher moisture) Non Lauric

Product Name TFA % Solid by NMR, typical value

20 oC 25 oC 30 oC 35 oC 40 oC

BiscuitineTM 621 29 58 41 23 9 0

CarabutaTM NH < 1 50 28 16 10 6

CLSPTM 620 6 60 30 10 4 1

CLSPTM 825 3 77 48 17 5 0

Non Dairy Creamer

Formulated based on hydrogenated palm kernel oil or olein with melting point of 35 – 42 oC

Higher melting fats required for shelf life, anti-clumping characteristics, and good dispersion in hot liquid

Product Name TFA % Solid by NMR, typical value

20 oC 25 oC 30 oC 35 oC 40 oC

CLSPTM 826 3 75 50 26 12 5

Whip able Toppings

Formulated based on hydrogenated palm kernel oil, hydrogenated palm kernel stearine, or blends of the two

Easy air incorporation during whipping and give high solids content required for foam stiffness

Product Name TFA % Solid by NMR, typical value

20 oC 25 oC 30 oC 35 oC 40 oC

CLSPTM 825 3 77 48 17 5 0

Ice Cream Mass

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Ice Cream Mass

“Ice cream is a frozen dairy food made by freezing a pasteurized mix under

agitation to incorporate air, ensuring uniformity and consistency”

Ice Cream Ingredients

FatMilk Solids Non FatSugarWaterEmulsifiers/Stabilizers FlavouringColouring

Fat in Ice Cream Milk Fat

• Milk • Cream • Butter • Anhydrous Milk Fat

Vegetable Fat

• Palm Oil • Palm Kernel Oil • Coconut Oil

Fats for Ice Cream Mass

Not the continuous phase 5-15% of the fat phase which determines the eating

quality

oHardness

oMeltdown Behaviour

oTexture

oBody

oMouthfeel

oCreaminess

oFlavour Release

Function of fat

oBuilding block for ice cream structure

oStabilize the air cell structure

oInteraction with protein and emulsifier

oImportant function during whipping and churning of ice cream

Product Name TFA SMP,oC % Solid by NMR, typical value

20oC 25oC 30oC 35oC 40oC

CLSPTM 625 <1 35 71 42 18 7 2

CLSPTM 710 <1 34 65 37 14 4 0

CLSPTM 720 8 33 65 37 14 4 0

CreameltTM 500 <1 29 45 26 6 1 0

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Fats for Ice Cream Mass

Recipe –Ice Cream Mass

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General Soft serve

Fat 10.0 12.0

Sugar 13.0 15.0

MSNF 10.4 11.0

Dextrose 3.5 -

Corn Syrup Solids - 3.0

Emulsifier/Stabilizers 1.0 0.4

Water 62.1 58.6

Ice Cream Coating

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Fats for Ice Cream Coating

Represent the continuous phase40 – 60% of the coating

determines the eating quality Hardness Meltdown behaviour Brittleness Flavor Release

Recipes – Ice Cream Coating

Ingredients %

Fat 55.0

Alkalized Cocoa Powder 10/12 8.0

Sugar 35.6

PGPR 0.75

Lecithin 0.14

Vanillin Optional

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Dripping & Drying

Dipping

+ 35 / + 45°C

Dripping time

Drying time

Packaging

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DRIPPING

DRYING

Let’s create togetherThank you

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