NevinBAŞARANR&DManagerinEFOBusinessUnit–YILDIZHOLDING

nevin.basaran@northstarinnovation.com.tr

EVALUATIONOFTHEPROPERTIES

OFCHOCOLATEPRODUCEDUSINGCBE

DEVELOPEDINBESLER‐TURKEY

OFI-ISTANBUL13th. May, 2014

AGENDAAGENDAFractionation Technology

Dry Fractionation of Fats

HPMF Production using Dry Fractionation and its Properties

Regulation of Chocolate in EU and TFC

Specialty Fats-Cocoa Butter Alternatives

BESLER CBE Production in the Pilot Plant

Chocolate Production using BESLER CBE in Chocolate Pilot Plant

Shelf Life Tests of Chocolates

Source: De Smet Group, 2003

OILMODIFICATION

HYDROGENATION

FRACTIONATION

Physical

Fractional crystallization

ChemicalINTERESTERIFICATION

Fatty acid redistribution

Chemical

POSTREFINING

DEODORISATION

MODIFIEDPRODUCT

Fully reversibleFully reversible

irreversibleirreversible

irreversibleirreversible

OILMODIFICATION

SOLVENT fractionation (acetone/hexane)‐crystallisation:continuous‐separation:vacuumbeltfilter

WET fractionation (NaLS/MgS)‐crystallisation:continuous‐separation:centrifuge

DRY fractionation (noadditives)‐crystallisation:batch(continuous)‐dynamicorstatic

‐separation:vacuumfilter/membrane/centr.

FRACTIONATION‐Technologies

Oil

Crystallisers

Statoliser

Filtration

OLEİN STEARİN

‐simplestandcheapestseparationtechnique

‐ environmentallyfriendly

‐nosupplementarypost‐treatment

‐partialcrystallisation

‐filteringinavacuumormembranefilterpress

DRY

Purelyphysicalprocess,no

chemicalsinvolved,‘Natural’

processundermild

conditions,Nopre/post‐

refiningrequired

Nooilloss,Fullyreversible

DRYFRACTIONATION‐Technologies

The dry fractionation or crystallisation from the melt is

the fat modification for the 21 st century

DRYFRACTIONATION

Vegetable Oil Dry Fractionation: Main Products

FractionsFractions Usage AreaUsage Area

COMMODITY OILSCOMMODITY OILS OleinsOleins Salad, Frying Oils,..Salad, Frying Oils,..

PALM OILPALM OIL

StearinsStearins Margarines, Shortenings,..Margarines, Shortenings,..

SPECIALITY FATSSPECIALITY FATS StearinsStearins CBS, CBR, CBE,..CBS, CBR, CBE,..

Low-medium pressure6-16 bars

High pressure>30 bars

PKSPKS Palm OilPalm Oil

CONFECTIONERY

ChangeinConsumertastes

Chocolateusedincombinationwithotherconfections(bakedgoods&candies...)

Makingsuchconfectionsoftenrequires

SPECIALITYFATS(CBE,CBS,CBR)SPECIALITYFATS(CBE,CBS,CBR)whicharewhicharecompatiblewithCocoaButtercompatiblewithCocoaButterand

makeitpossibletodevelopawiderrangeofdeliciousproducts…

SPECIALITYFATS

CBECBE CBRCBR

CBSCBS

SPECIALITYFATSSPECIALITYFATS

SPECIALITYFATS

USAGE of SPECIALITY FATS

Recent developmentsin the market place,

Availability,

Seasonal changes,

High raw material prices,

Technological innovations

USAGE of CBAUSAGE of CBA’’ssin confectioneryin confectionery

SFC of SPECIALITY FATS vs CB

Temperature, ºC

SFC, %

SFCGRAPHofthemixofCBE&CB

13

CBE is fully compatible with CB.

CBE AND ITS USAGE• The CBE fats are produced using proper combinations of shea stearine,

illipe butter, sal, mango and palm fractions in the world. All of these

vegetable fats are tropical based.

• Cocoa Butter Equivalents (CBE) are combinations of some vegetable fats

that have physical and molecular structure that are identical to those of

cocoa butter.

• During chocolate production CBE needs to be tempered as the same of CB.

• CBE is used for different purposes like more consistent chocolate,

preventing the formation of fat bloom, improving hardness and snap in

chocolate products, etc.

LEGISLATION OF CBE USAGE

TR: *Çikolata ve Çikolata Ürünleri Tebliği- Yetki Kanunu Türk Gıda KodeksiYönetmeliği- Yayımlandığı R.Gazete 17.07.2003-25171 Tebliğ No 2003/23Ürün Özellikleri / Madde 5/ d ve e

d) Kakao yağının dışında çikolata ürünlerine eklenecek bitkisel yağ listesi Ek-1 de verilmiş olup bitterçikolata, sütlü çikolata, bol sütlü çikolata, beyaz çikolatalara katılabilir. Kakao yağı veya toplam kakaokuru maddesinin minimum miktarını azaltmamak kaydıyla, yenilebilir diğer maddelerin toplam ağırlığınıtespit ettikten sonra bitkisel yağ ilavesi son üründe % 5 i geçemez.

REGULATION:REGULATION:

European directive 2000/36/EC and the Turkish Legislation specify that chocolate, milkchocolates - including plain chocolate-, white chocolate may contain:maximum of maximum of 5% vegetable fat 5% vegetable fat other than cocoa butter, illipe, palm oil, sal, shea,kokum gurgi, mango kernels and copra oil.

• Steep melting profile• Melting point 32 - 34ºC

• initial hardness and brittleness at an ambient temp.• a quick and complete meltdown in the mouth • a rich flavour release associated with the product• a glossy surface• a good snap

USAGE of CBA’s

FATS for CHOCOLATE

Cocoa butter

CBE (max.%5)

• Steep melting profile• Melting point 34ºC• Hard at room temperature

• Nice melt down Cocoa butter• No waxy feeling CBE types• Glossy surface CBR types• Good snap CBS types

USAGE of CBA’s COATING FATS for CHOCOLATE BARS

• Steep melting profile• Melting point 34ºC -36ºC• Hard/ semi hard at room temperature• Compatible with the filling

• Nice melt down Cocoa butter• No waxy feeling CBE types• Glossy surface CBR types• Good bite

USAGE of CBA’s COATING FATS for CHOCOLATE BARS ( candy bars)

• Moderate melting profile• Melting point 34 ºC -38 ºC• Hard/ semi hard at room temperature• Flexible / plastic

• Good melt down Cocoa butter• No or little waxy feeling CBE types• Glossy surface CBR types• Good bite Lauric Fats (HPKO)

USAGE of CBA’s COATING FATS for BISCUIT, CAKES and WAFERS

• Steep melting profile• Melting point 25 ºC - 28 ºC• Fast crystallisation

• Fast melt down Cocoa butter * + PK olein• Good flavour release CBE types * + Pk olein• Glossy surface HPKO - olein• Good snap Coconut oil

* not tempered

USAGE of CBA’s COATING FATS for ICECREAM

• Steep melting profile• Melting point 25ºC - 28ºC• Chocolatewithanonlaurictemperfilling• LauricCoatingwithalauricfilling,etc.

• Melt down Soft fractions of Palm Oil or Shea oil• Good flavour release Lightly hyd’d and frac’d BO or PO• Bloom Stability Coconut or PK oil• Cooling effect• Hardness

USAGE of CBA’sFATS for FILLINGS

BESLER CBE Project

Project Name: Cocoa Butter Equivalent Oil

Development – TUBITAK- TEYDEB 3110151

Project Time: 01.04.2011-15.04.20131.Stage: Research of Literature and Patents, Analysis of market products, Supply

of tropical fats.

2.Stage: Fraction Pilot Plant Trials for HPMF Optimization

3.Stage: CBE Formulation Trials

4.Stage: Chocolate production in chocolate pilot plant

5.Stage: Shelf life test of chocolates which are made with target and Besler CBE.

Project Name: CBE- Cocoa Butter Equivalent Oil

Development – TUBITAK TEYDEB 3110151

CBE PROJECT TEAM:

Nevin Başaran

Nurten Gökçen

Mehmet Ali Bayraktar

Mustafa Öztürk

Muzaffer Kamilçelebi

Hüsnü Mutlu

AIM OF PROJECT

To determine proper fractionation conditions for HPMF (Hard Palm

Mid Fraction) which is used in the CBE formula. (POP >61%, and

PPP < 2%).

To develop CBE similar to target CBE in the market.

To get more consistent chocolate, good hardness & snap, and

preventing the formation of fat bloom in chocolate products.

BESLER CBE PROJECT

Cocoa Butter Equivalent Oil Development Project

For these purposes;

- At the first stage of this project,

targeted Hard Palm Mid Fraction (HPMF) component was produced in

Besler Fractionation Pilot Plant.

-At the second stage,

different combinations of HPMF and tropical fats were studied in order to

obtain the optimum CBE formulation.

BESLER CBE Project

Palm Oil

Shea stearin,Illipe, etc.Top

Fraction OleinFraction

Hard Palm MidFraction (HPMF)

COCOABUTTEREQUIVALENTCOCOABUTTEREQUIVALENT

BESLER CBE ProjectPRODUCTION of CBE

After definition of the formulation and production of CBE, chocolate

trials were made using both developed and target CBE in our

chocolate pilot plant.

In the final products, the physical, chemical and sensorical

properties of the samples were analysed during production and end

of the shelf life.

BESLER CBE

CHOCOLATE TRIALS in PILOT PLANT

BESLER CBE24HPMFtrialsweremadeinourfractionationPilotPlant;

NO BLEND

ANALYSESRESULTSEND

PRODUCT

ANALYSESRESULTS

N20 N30 N35 SMP IV POO POP PPP N20 N30 N35 SMP IV POO POP PPP

1 %100TSPMF 15,20 0,00 0,00 23,00 50,60 18,00 41,60 0,60 HPMF 68,60 6,00 0,70 31,50 38,00 7,10 61,30 2,20

2 %100TSPMF 15,20 0,00 0,00 23,00 50,60 18,00 41,60 0,60 HPMF 61,00 3,50 0,20 30,00 42,50 10,20 55,80 1,80

3 %100SPMF 17,10 0,00 0,00 24,00 48,20 17,20 41,90 0,80 TSPMF 62,60 6,50 0,70 31,00 39,00 6,40 48,10 2,00

4 %80TSPMF+%20SPMF 21,00 0,00 0,00 26,00 48,00 16,70 41,50 1,20 HPMF 78,00 15,20 6,40 35,00 36,00 5,40 61,10 4,20

5 %80TSPMF+%20SPMF 21,00 0,00 0,00 26,00 48,00 16,70 41,50 1,20 HPMF 71,00 11,00 4,00 34,00 36,50 6,40 59,50 3,60

6 %80TSPMF+%20SPMF 21,00 0,00 0,00 26,00 48,00 16,70 41,50 1,20 HPMF 78,90 14,20 6,20 35,50 36,50 5,20 61,60 4,20

7 %80TSPMF+%20SPMF 21,00 0,00 0,00 26,00 48,00 16,70 41,50 1,20 HPMF 81,00 15,50 6,80 35,50 36,50 4,30 63,20 4,70

8 %100SPMF 21,00 0,00 0,00 26,00 48,00 16,70 41,50 1,20 TSPMF 78,90 15,30 6,40 35,00 36,00 5,50 61,30 4,30

9 %100TSPMF 17,10 0,00 0,00 25,50 47,00 16,40 42,20 0,90 HPMF 67,70 7,60 1,30 35,00 37,00 6,20 61,40 2,70

10 %100TSPMF 17,10 0,00 0,00 25,50 47,00 16,40 42,20 0,90 HPMF 71,00 8,30 1,60 35,50 36,00 6,20 60,90 2,80

11 %80TSPMF+%20SPMF 20,00 0,00 0,00 27,50 48,00 16,00 43,10 1,20 HPMF 77,00 14,80 6,60 35,00 37,00 4,30 56,30 4,00

12 %80TSPMF+%20SPMF 20,00 0,00 0,00 27,50 48,00 16,00 43,10 1,20 HPMF 82,30 18,00 8,60 34,50 37,50 3,60 58,30 4,80

13 %80TSPMF+%20SPMF 21,00 0,00 0,00 27,00 47,50 16,00 43,20 1,50 HPMF FAILED

14 %90TSPMF+%10SPMF 25,80 1,00 0,00 27,50 45,60 16,63 41,72 1,66 HPMF 68,00 13,00 5,50 34,50 36,10 8,70 56,50 3,90

15 %90TSPMF+%10SPMF 25,80 1,40 0,00 27,50 46,20 16,94 42,70 1,55 HPMF 70,00 15,40 7,10 34,00 35,70 7,10 57,80 4,40

16 %90TSPMF+%10SPMF 26,50 1,30 0,00 27,00 46,20 16,70 43,83 1,57 HPMF 75,60 15,00 6,10 35,00 36,00 5,80 61,00 4,60

17 %80TSPMF+%20SPMF 30,50 1,70 0,00 27,00 45,00 16,30 43,11 1,62 HPMF 67,00 12,50 4,80 34,50 35,50 7,80 58,00 4,80

18 %80TSPMF+%20SPMF 26,70 1,50 0,00 27,50 46,50 16,00 42,55 1,50 HPMF FAILED

19 %90TSPMF+%10SPMF 24,00 0,50 0,00 27,00 46,60 16,95 42,30 1,47 HPMF 70,00 21,20 11,80 35,50 35,00 7,61 54,00 6,10

20 %90TSPMF+%10SPMF 24,50 0,90 0,00 28,50 46,20 16,87 43,00 1,69 HPMF 70,50 14,00 6,60 34,50 34,50 7,37 55,43 3,93

21 %80TSPMF+%20SPMF 24,50 0,90 0,00 28,50 46,20 16,87 43,00 1,69 HPMF 71,40 10,60 4,10 34,00 34,50 6,79 58,43 4,48

22 %80TSPMF+%20SPMF 17,10 0,00 0,00 25,50 47,00 16,40 42,20 0,90 HPMF 71,00 8,30 1,60 35,50 36,00 6,20 60,90 2,80

23 %100TSPMF 19,60 0,60 0,00 24,00 48,50 16,40 40,40 0,80 HPMF 83,00 15,00 4,70 35,00 32,40 3,52 64,75 2,16

24 %80TSPMF+%20SPMF 23,20 0,70 0,00 28,50 45,10 15,46 38,88 1,36 HPMF 71,40 10,65 4,10 35,50 35,40 6,79 58,43 4,48

ProductnameCOCOABUTTER TARGET 1 2 3 4 5 6 7 8

CBENr 1

CBENr 2

11 12

I.V.(Wij’s) 30-36 30-36 34,20 33,90 34,10 34,00 33,80 35,10 34,00 33,85 34,90 35,50 35,60 35,80

SMP(°C) 32-34 33-35 26,50 27,00 28,00 28,00 28,00 31,00 29,00 27,50 30,50 32,00 32,50 33,50

NMR(IUPAC2.150a)10(°C) 87,10 88,10 86,90 88,50 87,40 87,00 89,80 89,20 80,50 83,70 84,00 89,00

20(°C) 30,30 30,00 34,50 40,00 32,00 53,00 39,70 26,30 57,30 59,00 61,80 58,40

30(°C) 0,50 0,60 1,40 0,70 0,50 3,70 0,20 0,30 6,20 7,00 13,00 6,00

35(°C) 0,00 0,00 0,00 0,00 0,00 1,20 0,00 0,00 1,90 2,00 2,10 1,80

NMR(IUPAC2.150b)10(°C) 81,10 83,80 82,30 82,10 82,10 83,80 80,00 85,10 83,05 81,30 82,20 80,80 80,00

20(°C) 60‐70 70,00 48,80 60,00 57,30 62,00 66,00 60,00 68,10 62,00 60,00 60,50 64,00 62,00

30(°C) 30‐40 49,20 14,70 26,80 30,00 36,35 20,20 39,20 36,45 25,60 30,00 31,00 39,00 32,00

35(°C) max. 2 17,90 1,70 0,30 4,20 3,60 0,10 12,90 0,30 0,00 8,10 6,60 7,00 6,50

GCC‐12:0 0,07 0,10 0,10 0,10 0,20C‐14:0 0,33 0,44 0,44 0,44 0,42 0,62 0,35 0,57 0,48 0,35 0,29 0,28 0,32

C‐16:0 23,26 33,96 34,56 32,34 33,18 46,34 26,59 43,47 37,42 23,09 21,00 18,00 22,02

C‐18:0 39,42 28,99 27,88 31,00 30,10 17,63 36,75 20,12 25,94 39,95 42,50 44,81 41,07

C‐18:13 0,32 0,38 0,22

C‐18:1 32,43 33,44 33,73 32,80 33,58 33,27 32,81 33,59 33,74 33,05 33,03 33,07 33,05

C‐18:2 3,27 1,75 1,96 2,57 1,65 1,40 2,45 1,40 1,35 2,45 2,50 2,56 2,40

C‐18:3 1,28 1,00 1,00 0,99 1,08 0,75 1,10 0,86 1,10 1,10 1,18 1,23 1,14

C‐20:0

SATURATEDFAT 60‐65 63,01 63,46 62,98 63,88 63,70 64,59 63,69 64,16 63,84 63,49 63,99 63,09 63,41

UNSATURA.FAT 32-36 36,98 36,51 37,07 36,58 36,31 35,42 36,36 35,85 36,19 36,51 36,71 36,86 36,59

PUFA Max. 5 Max.4

TRANS 0 0,00 0,32 0,38 0,22 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00 0,00

POP 20,7 37,29 36,06 35,6 51,00 49,46 27,27 44,52 35,64 24,77 22,40 18,70 23,54

POS 3,0 17,41 19,01 14,83 18,20 17,48 3,06 18,75 21,56 2,94 3,08 3,53 3,75

SOS 44,0 30,86 26,43 33,00 14,00 13,72 39,82 16,51 22,47 42,60 49,10 50,25 48,24

ANALYSIS RESULTS OF CBE COMPOSITIONS

ANALYSES OF BESLER CBE Product

Belowanalysesweremade;• Fatty acid composition (GC),

• Solid fat content (SFC, NMR),

• Particle size,

• Iodine value (IV),

• Trigycerid content,

• Viscosity,

• Moisture,

• Texture (hardness),

• Colour and glossiness,

• Sensorical evaluations of chocolates (melting behaviours, mouthfeel,

snap, brittleness, stickness, etc.).

31

COOLING CURVE

32

SFC VALUES OF CBE’S

Temperature

SFC

BESLER CBE Project

Chocolate Trials at Besler Pilot PlantChocolate Formulation*:

*Industrial Chocolate Manufacture and Use (page.343, S.T Beckett, 3. Baskı, Blackwell Science, 1999)

Cocoa butter & 5% Besler CBECocoa butter & 5% Target CBE

COCOABUTTER %8,04

CBE %5

COCOAMASS %43,18

SUGAR %43,40

LECITHINE %0,38

BESLER CBE Project

Cocoa Butter Equivalent Oil Development

RESULTS:After all trials, we also analysed the properties of the final

chocolate products during shelf life.

At the end of the chocolates shelf life :

It was found to have very similar results in the chocolates

made both target and Besler CBE sample Nr 1.

BESLER CBE Product and its properties

Sensorical Analyses

BESLER CBE Product and its propertiesAnalyses results (Chocolate) after Shelf Life (6 months)

SAMPLEViscosity

(cp)YieldValue

MOISTURE%

İNCµ FLAVOR FAT% COLOR

CHOC‐TARGET 16,92 74,09 0,59 23 22,3 36,98 L:19,81a:14,02b:18,51CHOC‐CBE1 17,08 58,92 0,64 25 23,2 37,02 L:18,59a:13,50b:17,19CHOC‐CBE2 16,11 20,54 0,54 27 26,6 37,24 L:19,07a:14,07b:18,52

SampleNrCBENr1 Temperature°C

Fi3Max.Force Fi5MinForce Hardness

mN mN mNCHOC‐TARGET 30 7443 3586 7443CHOC‐‐CBE1 30 7030 3323 7030CHOC‐CBE2 30 6466 2901 6466

CHOC‐TARGET 29 7292 2543 7292CHOC‐‐CBE1 29 6735 2699 6735CHOC‐CBE2 29 6896 3308 6896

CHOC‐TARGET 28 11097 4479 11097CHOC‐‐CBE1 28 10901 4055 10901CHOC‐CBE2 28 8922 3207 8922

CHOC‐TARGET 32 1560 732 1560CHOC‐‐CBE1 32 1442 721 1442

Chocolate trials after 6 months

BESLER CBE

TARGET SAMPLE CBE-1 SAMPLE CBE-2 SAMPLE

ASARESULT;

•WecanproduceagoodqualityBESLERCBEproductinourfractionationplantinBESLERFactory.

•Now,BeslerCBEiscommerciallyavailableinTurkey.

•Itısapprovedbysomeofchocolateproducercustomers.

BESLER CBE

BESLER CBE SPECIFICATIONTEKNİK / DUYUSAL ÖZELLİKLER / TECHNICAL / SENSORIAL CHARACTERISTICS

ANALİZ YÖNTEMİ / ANALYSISMETHOD

Tat ve koku / Taste and Odour Bland

% Yağ min. 99,9

% Fat Content

Serbest yağ asidi, % max. 0,10 AOCS Ca 5a-40

(palmitik asit cinsinden)

Free fatty acids, FFA %

(as palmitic acid)

Peroksit değeri (meqO2/ kg) 0 (üretim tarihinde / at the production date) AOCS Cd 8-53

Perokside value (meqO2/ kg) max.1 (yükleme tarihinde / at the shipment date)

% Katı Madde Miktarı / SOLID FAT CONTENT, % IUPAC 2.150 b

N10 78-82

N20 58-65

N30 27-34

N35 6-12

THANK YOU THANK YOU FOR YOUR KIND ATTENTION FOR YOUR KIND ATTENTION

nevin.basaran@northstarinnovation.com.trnevin.basaran@northstarinnovation.com.tr

CBE

CBR

CBS