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This book is about basics of confectionery technology. The book is systematically designed into various chapters like manufacturing of sugar, various sweeteners used in confectionery, release agents used in confectionery, whipping agents, glucose syrup, cocoa bean processing, tableting, panning and packaging requirements of confectionery products, etc. All the content is explained in simple and understandable language. This edition also contains an exhaustive index and references. This book is helpful to all students, staff, individuals for basics of Confectionery Technology.

Confectionery is the art of making confections, which are food items that contains high quantity of sugar and carbohydrates. Traditional confectionery goes back to ancient times, and continued to be eaten through the Middle Ages into the modern era. Confections include sweet foods, sweetmeats, digestive aids that are sweet, elaborate creations, and something amusing and frivolous. Confectionery, delicacies or sweetmeats that have sugar as a principal ingredient, combined with coloring matter and flavoring and often with fruit or nuts. Confections are low in micronutrients and protein but high in calories.

2.1 Manufacturing Process of Sugar There are a number of steps in producing raw sugar from cane Sugarcane receiving and unloading (receive the cane at the factory and unload it from the transport vehicles) Sugarcane preparation (cutting and shredding cane to prepare it for juice extraction) Extraction of Sugarcane Juice (two technologies are in common use; milling or diffusion) Juice clarification (remove suspended solids from

1.3 Dextrose Sweets which include dextrose have different eating qualities to those made with sucrose and glucose syrup alone. Recipes should be balanced so that the sucrose to dextrose ratio achieves the required product texture. The incorporation of dextrose will increase the likelihood that crystallization will occur either on store or during manufacture. Replacement usage levels for dextrose normally lie between 5% and 15% of the Sucrose content

Definition ‘Whipping agent’ are a wide variety of materials to describe their role in confectionery manufacture as a means of holding air introduced into a product, to produce a uniform dispersion of air cells within the confection leading to a lower specific weight and considerable modification to the texture. Stable foams cannot be obtained by whipping high concentration sugar solutions without the presence of a ‘surface-active’ agent. Many types of proteins have whipping properties and those used in the sweet industry are: (a) Egg albumen, crystal powdered and spray dried; (b) High Bloom gelatine and gelatine hydrolysates; (c) Skimmed milk in spray dried form; (d) Whey, or whey in a mixture with skimmed milk;

Release agents are used to grease equipment used for manufacturing certain types of sugar confectionery for easy removal of the sweet. High-viscosity, purified mineral oil is most commonly used material suitable for all sweet manufacturing purposes. Mineral oil is neutral in taste and has little odour. It should be used carefully: there is a legal limit of 0 2% in the United Kingdom. Acetylated mono-glycerides have excellent release properties. A number of alternatives based on vegetable oil are available, but the development of rancidity on the film surface on the sweets during storage is the major difficulty in the use of vegetable oil

The first use of milk in a solid chocolate product is commonly attributed to Daniel Peter in 1875. Milk chocolate is the most popular type of chocolate, and milk ingredients are critical in delivering the highly desired properties and taste profile to consumers. Milk ingredients also have a significant effect on chocolate processing. Milk is one of the most complex raw materials used by the food industry. A typical bovine whole milk has a solids content of about 13.5%, comprising about 3.4% protein, 4.6% fat, 4.7% lactose and 0.7% minerals. Milk proteins can be classified as either caseins or whey proteins - typically found in milk

These hydrolysates are dried conversion products available in a powdered form. Up to 20 DE they are normally referred to as malto-dextrins or hydrolised cereal solids. Above 20 DE they are more commonly termed spray dried glucose syrup solids. Applications Spray dried hydrolysates find application in a wide range of processed and convenience foods. Principally as filler/carrier and sweetness reducer. They are ideally suited for blending into powdered formulations, and serve the following purposes. As filler/carrier, they can (1) Reduce loss of volume in contents on storage or in transit; (2) Absorb fats and oils to retain free-flowing properties;

A glucose syrup is defined as ‘A purified and concentrated aqueous solution of nutritive saccharides derived from starch’, and having the following characteristics: Dry matter of not less than 70%. A dextrose equivalent (DE), expressed as d-glucose, of not less than 20% based on dry matter. A sulphated ash content of not more than 1% on a dry basis. Starch has a DE value of zero, whilst dextrose, the final end product of starch hydrolysis, has a DE value of 100. For the lay person, the term dextrose equivalent or DE can be regarded as an indication of how far the conversion process from starch to dextrose has gone. While technically DE is a measure of the total reducing sugars present in a glucose syrup.

Introduction Botanical name of cocoa is Theobroma cacao and family is Malvaceae. The cocoa bean, also cacao bean or simply cocoa or cacao, is the dried and fully fermented fatty seed of Theobroma cacao, from which cocoa solids and cocoa butter are extracted. Cocoa flavour is the most distinct feature of chocolate, thus cocoa beans are the basis of chocolate. Dried cocoa beans are usually processed into cocoa butter, which contains fat between 56% and 58%, made up of a mixture of triglycerides. Cocoa butter with this composition is good for making chocolate and has favourable hardness and a melting point of body temperature. Theobroma cacao originated from the Jungle of the Amazon in Brazil. Theobroma cacao consists of two subspecies: the Cacao, a subspecies known as the Criollo, which can be found in Central and South America, and spharocarpum, which is also called theForastero. The Criollo has superior and fine flavour. The pods are red and the beans have no color. Forastero has a green pod

Dried Cocoa Bean have chemical composition as: The shell (testa) represents 10-14% dry weight of the cocoa bean, while the kernel or cotyledon is made up of most of the remaining 86-90%. The cotyledon confers characteristic flavours and aromas of chocolate and is composed of two types of parenchyma storage cells. Before processing, the quality ofbeans is evaluated for the following indicators: Degree of fermentation Moisture content (maximum 6%) Number of defects Number of broken beans Bean count (number per 100 g)

Cocoa butter, also called the obroma oil, is a pale-yellow, edible fat extracted from the cocoa bean. It is used to make chocolate, as well as some ointments, toiletries, and pharmaceuticals. Cocoa butter has a cocoa flavor and aroma. Its melting point is just below human body temperature. Cocoa butter that has been refined by neutralization with an alkaline solution and decoloured with for example bentonite, activated carbon etc. Subsequent deodorization can also be applied. The type of process used may affect the quality of the cocoa butter. For example, a too high deodorization temperature or a too severe alkalization can completely alter its setting (solidification) characteristics. High-quality raw materials are needed to make the best quality cocoa butter. The other important factors for high quality are the origin of the beans and the processing conditions used. Press cocoa butter, which is most commonly used in the chocolate industry, is only filtered and (partly) deodorized to obtain the desired flavour. Cocoa butter contains a high proportion of saturated fats as well as monounsaturated oleic acid, which typically occurs in each triglyceride.

The development of a recipe for chocolate should be based on three criteria: (i) The intended market or use; (ii) The limitation being placed on material and production costs; (iii) The desired quality. The amount of fat present in the chocolate will affect the flow properties, and fat content must therefore be varied according to the intended use. Some point to remember while manufacturing chocolate: To maintain proper viscosity if fat content is increased then sugar content should also be increased. Milk chocolate requires lower fat content than dark chocolate. Addition of emulsifier like commercial lecithin can save upto 5% of added cocoa butter.

Chocolate is almost unique as a food in that it is solid at normal room temperatures yet melts easily within the mouth. This is because the main fat in it, which is called cocoa butter, is essentially solid at temperatures below 25oC when it holds all the solid sugar and cocoa particles together. This fat is, however, almost entirely liquid at body temperature, enabling the particles to flow past one another, so the chocolate becomes a smooth liquid when it is heated in the mouth. Chocolate also has a sweet taste that is attractive to most people. The first known cocoa plantations were established by the Maya in the lowlands of south Yucatan about 600 AD. Cocoa trees were being grown by the Aztecs of Mexico and the Incas of Peru when the Europeans discovered central America. The beans were highly prized and used as money as well as to produce a drink known as chocolatl. The beans were roasted in earthenware pots and crushed between stones, sometimes using decorated heated tables and mill stones, similar to those illustrated in Figure 1.1.

The art in producing high-boiled sweets with satisfactory shelf life is manufacturing boilings which contain the minimum amount of residual moisture and a satisfactory balance between cane or beet sugar, and glucose syrup or invert sugar syrup. The main physical change during the storage of high-boiled sweets is the formation of small crystals in the confection, usually referred to as graining, due to recrystallisation of sucrose. These spoil the appearance and cause an unpleasant roughness on the tongue. For high-boiled sweets it is impossible, using the normal proportions of cane or beet sugar (sucrose) and glucose syrup, to obtain a product of 97% solids content, which is not supersaturated with respect to sucrose. In practice, however, one-and-a-half parts of sugar (sucrose) to one part of forty-two DE glucose syrup will produce a high-boiled sweet stable against graining.

15.1 Fondant The word fondant is said to come from the French verb fondre to dissolve. Confectionery fondants are normally made by boiling a sugar and glucose syrup in order to concentrate it before the mixture is cooled with beating to produce fine sucrose crystals. Some fondants used in baking are made by mixing icing sugar with a sucrose and glucose mixture. The icing sugar has a small particle size because it has been milled whereas the sucrose in a crystallised fondant has small crystals. It is possible to make a fondant using dextrose instead of sucrose. Crystalline dextrose has a positive heat of solution, i.e. heat is absorbed, and this produces a marked cooling effect which goes well with a peppermint flavour, but one which is not particularly attractive economically, but they can be in some other countries.

Lozenges are solid preparations that contain one or more medicaments, usually in a flavored, sweetened base, that are intended to dissolve or disintegrate slowly in the mouth. They can be prepared by molding (gelatin and/or fused sucrose and sorbitol base) or by compression of sugar-based tablets. Molded lozenges are sometimes referred to as pastilles, whereas compressed lozenges may be referred to as troches. They are used for patients who cannot swallow solid oral dosage forms well as for medications designed to be released slowly to yield a constant level of drug in the oral cavity or to bathe the throat tissues in a solution of the drug. Lozenges historically have been used for the relief of minor sore throat pain and irritation and have been used extensively to deliver topical anaesthetics and antibacterial. Advantages It is easy to administer to both paediatric and geriatric patients. It has a pleasant taste and will extend the time a quantity of drug remains in the oral cavity to elicit local activity.

Tabletting is the area where sugar confectionery and pharmaceutical manufacture come closest, as the machines are similar the process can also be similar. Confectioners normally try to make tablets as hard as possible whereas pharmaceutical tablets are normally made to be fairly soft. Tablets are made by compressing a powder in a die. Under pressure the powder fuses and is ejected as a tablet. The problem of tabletting is to produce a powder that will flow freely when poured into the die but bonds satisfactorily when compressed. Some materials are available in a directly compressible form. One example is sorbitol, which goes some way to explain the popularity of pressed sorbitol tablets with manufacturers. If directly compressible materials are not being used then the material must be granulated before being tabletted. Granulation Tabletting materials can be prepared by a number of different methods as outlined below:

These products were originally flavoured with the herb marshmallow but a modem marshmallow is a foam that has been stabilised by a gelling agent. The traditional material for marshmallows is egg albumen which acts both as a foaming and gelling agent - this gives light, soft gel. Gelatine is now more commonly used, and once again can act as both a whipping and gelling agent. A gelatine marshmallow is soft and rubbery but heavier than an egg albumen one. Further gelling agents, e.g., pectin, agar and starch all give a soft, short textured gel. These gelling agents have the advantage of being vegetable products but have the disadvantage of normally needing a whipping agent as well. Enzyme-modified soya products have also recently become available for this use. Methods of Marshmallow Manufacturing:

This process involves building up a coating of sugar and sometimes of other things, layer by layer. Panning is one of those processes that the confectionery and pharmaceutical industries have in common. The coating of confectionery with sugar using a pan is very ancient. Originally, these products were made in an open pan suspended over a fire by chains. Apparently the operator swung the pan by hand, coating the product with sugar syrup which was then allowed to crystallise. The normal modern small-scale method is to use a rotating dragee pan (Fig.No.19.1). These are elliptical vessels made traditionally of copper, but now more commonly of stainless steel. The pan is equipped to be rotated and usually there is a system for supplying and extracting air and possibly with a system for spraying in the sugar syrup. Typical pan sizes are between 1.5 and 0.9 m in diameter although smaller sizes are used for small-scale work.

Product Characteristics and Packaging Requirements: The key raw materials for sugar confectionery are sugar (60 - 65%), glucose, citric acid and flavoured essences. Confectionery is hygroscopic in nature and requires protection against the ingress of moisture, and exposure to high temperature (as far as possible). A candy or confectionery product may be adversely affected by many things. Hard candy, brittles and crunch products are most sensitive to moisture and absorb water vapour fairly rapidly from the atmosphere. Various gums are less sensitive while some creams tend to lose moisture considerably.

Beckett S.T. (2009). Industrial Chocolate Manufacture and Use (4th Edition), Blackwell Publishing Ltd. Beckett S.T. (2009). The Science of Chocolate(2nd Edition), RSC Publishing. Bernard M. Minifie (1989). Chocolate, Cocoa and Confectionery Science and Technology (3rd Edition)