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Hard Candy Lab II - Fruit Flavors and Acidulants<br />
Without acidulants, fruit flavored confectionery products would<br />
be dull, non-descript, non-characteristic and unusually sweet.<br />
To achieve an optimal fruit flavor, it is essential to balance<br />
the sugar and the acid with the specific fruit flavor. <strong>Citric</strong><br />
acid with its high level of tartness, over rules the more<br />
delicate flavors such as strawberry and watermelon, but is ideal<br />
in orange and lemon. Malic and lactic, with more subtle<br />
sourness, are better suited in milder berry flavors.<br />
The consumer expects a certain level of tartness from various<br />
fruit flavors. It is natural to use the food acid that is<br />
<strong>com</strong>monly found associated with the fruit in nature. For<br />
example, citric acid in orange, lemon and grapefruit flavored<br />
candies, tartaric and malic acid in grape and malic acid in<br />
apple, cherry and watermelon.<br />
The product developer is not limited to this, however. Knowing<br />
the flavor profile of the acids, a logical choice can be made.<br />
Tartaric acid is perceived very quickly and with high intensity<br />
but fades quickly. <strong>Citric</strong> acid is perceived very quickly as<br />
well with an intensity not quite as high as tartaric but with<br />
more staying power on the palate. Malic and lactic acid are<br />
perceived slowly but linger for a longer time period.<br />
Many confections contain blends of acids that result in the<br />
desired <strong>com</strong>bination of intensity, duration and flavor masking.<br />
In this lab we will make 9 <strong>com</strong>binations of fruit flavored hard<br />
candy, consisting of three different flavors and 3 different<br />
food grade acids, all at an equal 1% level. We will taste these<br />
different grades observing the various effects the acid has on<br />
flavor perception, intensity, release and duration.
Hard Candy II Lab - Flavors/Acids<br />
Objective: To determine the effect of acid/flavor <strong>com</strong>binations on flavor<br />
perception, release, intensity, and duration.<br />
Ingredients:<br />
Basic Hard Candy Formula<br />
Sucrose 819 g<br />
Corn Syrup, 42 DE 540 g<br />
Water 245 g<br />
Total 1604 g<br />
Formula Flavor Rotation 1 Rotation 2 Rotation 3<br />
A Orange 0.6% (7.8 g) No Acid No Acid No Acid<br />
B “ 1.0% (16 g)<br />
<strong>Citric</strong><br />
1.0% <strong>Citric</strong> 1.0% <strong>Citric</strong><br />
C “ 1.0% (16 g)<br />
Malic<br />
1.0% Malic 1.0% Malic<br />
D Grape 0.5% (6.5 g) No Acid No Acid No Acid<br />
E “ 1.0% (16 g)<br />
<strong>Citric</strong><br />
1.0% <strong>Citric</strong> 1.0% <strong>Citric</strong><br />
F “ 1.0% (16 g)<br />
Malic<br />
1.0% Malic 1.0% Malic<br />
G Watermelon 0.6%<br />
(7.8g)<br />
No Acid No Acid No Acid<br />
H “ 1.0% (16 g)<br />
<strong>Citric</strong><br />
1.0% <strong>Citric</strong> 1.0% <strong>Citric</strong><br />
I “ 1.0% (16 g)<br />
Malic<br />
1.0% Malic 1.0% Malic<br />
Equipment:<br />
Copper cooking kettles<br />
Gas burner<br />
Stirring spoon<br />
Thermometers<br />
8 oz. glass jars<br />
Methods:<br />
The base hard candy formulations (dry basis formula 65% sucrose / 35%<br />
42/43 corn syrup) have been preweighed for you in the copper kettles.<br />
Stir the mixture slowly as it heats. When the sugar is <strong>com</strong>pletely<br />
dissolved, it is no longer necessary to stir. Keep the flame rather low,<br />
between 230 and 250ºF, because there will be moderate foaming.<br />
After foaming has subsided, the gas fire can be increased slightly.<br />
Continue cooking until the mixture has reached 305°F. Immediately turn off<br />
the burner, carry the kettle to the cooling table and pour out mixture. Add<br />
the flavor and acid corresponding to your group and fold it into the cooked<br />
mass using a spatula. Adding a small amount of hard candy scrap to the melt<br />
will help absorb liquid flavor and acids during addition and mixing.<br />
When the candy is cool, break into pieces to fill an 8 oz. jar identified<br />
with your code number. These jars will be used for classroom discussion with<br />
the instructor.
Observations: Describe your results in the following table.<br />
Flavor<br />
Perception<br />
Flavor<br />
Intensity<br />
Flavor<br />
Release<br />
Flavor<br />
Duration<br />
A B C D E F G H I
Flavors and Acids<br />
Hard Candy Lab 2<br />
Discussion<br />
Allan Buck<br />
Archer Daniels Midland Co.<br />
Resident<br />
Course in<br />
Confectionery<br />
Technology<br />
Resident Course in Confectionery Technology
Flavors and acids<br />
• <strong>Citric</strong> - orange, lemon, lime<br />
• Malic - apple, strawberry, cherry<br />
• Tartaric - grape<br />
• Lactic - milk based flavors<br />
Resident Course in Confectionery Technology
Acid Intensity<br />
7<br />
6<br />
5<br />
4<br />
3<br />
2<br />
1<br />
0<br />
Flavor Profile of Acidulants<br />
0 2 4 6 8 10 12<br />
Lasting Time<br />
Resident Course in Confectionery Technology<br />
Tartaric<br />
<strong>Citric</strong><br />
Malic<br />
Lactic
Example of Inverting Effect of Acids<br />
Orange Flavor<br />
No Acid<br />
<strong>Citric</strong> Acid<br />
Malic Acid<br />
Tartaric Acid<br />
Buffered Lactic Acid<br />
Source: NCA Candy School 2001 – Lab II experiments<br />
% Inverted<br />
5%<br />
20%<br />
18%<br />
15%<br />
5%<br />
Resident Course in Confectionery Technology
Rework Reclamation by P. Srnak<br />
Even the best hard candy system will generate a certain quantity of out-ofspecification<br />
goods. How a manufacturer handles these goods will largely be<br />
determined by economics. Often, however, having some type of rework reclamation<br />
procedure will be necessitated, and this section will outline some of the options<br />
available. The procedures outlined will work equally well with both sugar and most<br />
sugarfree products. Throughout this discussion, the term “rework” and “scrap” will be<br />
used interchangeably. It should be noted that oftentimes candymakers shun the term<br />
“scrap” because of its negative connotations.<br />
• Like-into-Like rework usage. Simply fold your deformed candy into subsequent<br />
batches. This is the cheapest, simplest and most cost-effective system, but it has<br />
some important drawbacks:<br />
1) Any contaminates that were present on the surface of the scrap, or were<br />
traveling along with the scrap will now be worked into the finished goods.<br />
2) If your candy has a high sugar to corn syrup ratio, or contains a<br />
crystallizing polyol, then there is the possibility of inducing unwanted<br />
graining in your finished goods.<br />
3) You need to have similar batches to work your scrap into, and there is a<br />
limit to how much you can use. This is a problem with short runs or unique<br />
items. Striped or multicolored goods can be very hard to rework this way.<br />
4) This system works best if the scrap is ground into small chips to allow for<br />
more uniform mixing, and if it is added while the freshly cooked batch is hot<br />
enough to ensure <strong>com</strong>plete melting. Of course, introducing a grinder into<br />
the production process also increases the risk of incorporating tramp metal<br />
into the product, so that a finished product metal detector is highly<br />
re<strong>com</strong>mended.<br />
5) Finally, you must be very careful to avoid the introduction of unlabeled<br />
allergens.<br />
• Liquid Scrap Reclaiming. This is often a better way to utilize out-of-specification<br />
candy. With a liquid scrap system you dissolve your rework in water and then<br />
treat and filter the solution. The treatment will remove flavors and colors and<br />
adjust the pH while the filtering will remove particulates (including the treatment<br />
<strong>com</strong>pounds). The resulting liquid can be added back to the syrup feed stream<br />
prior to cooking, and will generally be free from the drawbacks experienced with<br />
the handling of solid rework. A liquid scrap system consists basically of a<br />
dissolving/mixing kettle, a filtering or adsorption system, and a receiving tank.<br />
Activated carbon, in either powdered or granulated form, is used to adsorb the<br />
unwanted flavors and colors. These systems are described in more detail below.<br />
Components of a Liquid Scrap Reclamation System:<br />
1) Processing Aids<br />
(a) Activated Carbon. Activated carbon is a very porous material. It<br />
functions by allowing undesirable flavor or color molecules to enter<br />
these pores, and then retains them via weak electrostatic forces. The<br />
high porosity of activated carbon gives it a tremendous absorptive
surface area, (in the range of 500-2,000 m 2 /g for the powdered<br />
product). Activated carbon is available in many different pore sizes and<br />
grinds so that it can be custom-matched to a specific application. For a<br />
filter-type system a fine powder is generally desired while the granular<br />
form is better suited for an absorptive column.<br />
(b) Filter Precoat. A filter precoat is used with filter-type rework systems.<br />
The most <strong>com</strong>mon material used for filter precoating for hard candy<br />
reworking is diatomaceous earth, or filter-aid. In practice, a supporting<br />
surface (either a filter pad or a fine mesh screen) has a filter cake of the<br />
precoating material built up on it. The carbon/rework slurry is then<br />
forced or drawn through the filter cake with the flavor and color loaded<br />
carbon being retained while the clear solution is allowed to permeate.<br />
The filter cake acts as a depth-type filter, while retained carbon acts as<br />
a sort of dynamic filtering surface. The amount of filter precoat required<br />
is dependent on the equipment being used since the entire filtering<br />
surface must be coated. Additional precoat is often added to the rework<br />
syrup at a rate of 0.25 – 0.35% of the rework solids.<br />
(c) Neutralizing Agents. When using rework syrup, it is important to<br />
neutralize any acids that may have been present in the scrap candy to<br />
avoid inversion during cooking. However, because activated carbon<br />
works better at a lower pH, (2-3 is ideal), it is re<strong>com</strong>mended that the<br />
neutralizing be done after the carbon is filtered off. The table below can<br />
be used to determine the amount of neutralizing agent required:<br />
Sodium Sodium Sodium<br />
Sodium Carbonate Carbonate Calcium Hydroxide<br />
Acid Bicarbonate (Anhydrous) (Monohydrate) Carbonate C.P.<br />
<strong>Citric</strong> Acid (Anhydrous) 21 13.2 15.5 12.5 10<br />
Tartaric Acid 17.9 11.3 13.2 10.7 8.5<br />
Lactic Acid (50%) 7.5 4.7 5.5 4.4 16.7<br />
Malic Acid 20 12.7 14.8 11.9 9.5<br />
Ounces of alkaline salts per pound acid<br />
2) Equipment<br />
a) Filter Press. A filter press is one of the simplest types of reclamation<br />
equipment available. Presses use either disposable paper or washable<br />
fabric filter materials, and consist of several divided sections which<br />
either carry the rework slurry or the filtered permeate (filtrate). They<br />
have a decent surface area in a fairly <strong>com</strong>pact unit and are easy to<br />
maintain and clean. Unfortunately, these types of filters tend to plug<br />
easily. Therefore if dealing with rework containing wrapping materials or<br />
with rework that contains any particulates, screening or prefiltering may<br />
be necessary to avoid excessive drops in permeate flow rates.<br />
b) Rotary Vacuum Filter. This is old technology that is still unmatched in<br />
performance today. A rotary vacuum filter consists of a segmented,<br />
filter-covered drum that is slowly rotated through the feed slurry while<br />
applied vacuum draws permeate through it. Rotary vacuum filters are<br />
available with many different filtering surfaces utilizing various retentate
emoval systems. However, hard candy is best filtered using what is<br />
called a “pre-coat filter” equipped with a doctor blade, (see drawing).<br />
With this system, filtering begins by first filling the reservoir with a filteraid<br />
slurry. Applied vacuum will then build up a thick cake on the surface<br />
of the filter. Once the cake is formed, the reservoir is filled with the<br />
carbon-rework slurry and the doctor blade is slowly advanced toward<br />
the drum surface. With each turn, the doctor blade removes a thin layer<br />
of thick precoat cake along with any particulates that had deposited on<br />
the surface. This basically results in a never-ending fresh filtering<br />
surface. Because the maximum pressure driving the permeate through<br />
the filter is atmospheric, this system works best with low solids rework<br />
syrups (
there is no carbon dust. If a <strong>com</strong>pany has a uniform rework stream with<br />
only a limited amount of flavors or colors to remove, then a carbon<br />
column may be worth examining.<br />
3) Rework Process.<br />
a) Step 1: Sort your rework. Try to get a consistent raw material so that<br />
you can standardize your process.<br />
b) Step 2: Hydrate your carbon. Carbon must be thoroughly wetted to<br />
work.<br />
c) Step 3: Dissolve your rework. Use lots of agitation but avoid high<br />
temperatures. There are two reasons to avoid hot water. First, activated<br />
carbon works best at lower temperatures. The absorption process is a<br />
dynamic process…molecules enter the pores and exit the pores,<br />
eventually reaching equilibrium. Heating the solution shifts the process<br />
more toward desorption. The other reason to avoid high temperatures is<br />
to minimize inversion of the sucrose when dealing with regular candy<br />
scrap.<br />
d) Step 4: Allow the carbon time to adsorb flavors and colors. Adsorption<br />
follows sort of a logarithmic curve, so that it is important to allow<br />
enough time for maximum adsorption to occur. Start with at least 1<br />
hour. Stir constantly to ensure that the carbon is allowed to <strong>com</strong>e in<br />
contact with the undesirable <strong>com</strong>ponents and to keep it from settling on<br />
the bottom of your kettle. With an absorptive column, the unit must be<br />
sized to ensure that the syrup has a residence time of at least 1 hour<br />
before it exists when the unit is operating at the desired production rate.<br />
With adsorptive columns, skip to Step 7.<br />
e) Step 5: If applicable to the chosen system, precoat your filter.<br />
f) Step 6: Begin filtering. Return the permeate to the feed tank until it<br />
begins to run clear. If necessary, you can add more carbon and start<br />
over. Remember that the carbon will build-up on the diatomaceous<br />
earth precoat and form a dynamic filtering surface, so that the permeate<br />
must be recycled briefly.<br />
g) Step 7: Use your rework in a timely fashion because with a solids of<br />
only ~50%, it is far from bacteriologically stable.<br />
• Other Rework Strategies. Rework does not need to be used back into hard<br />
candies. For example, rework can be used in jelly fillings to replace some or all of<br />
the required sugar and corn syrup. Because hard candy rework is usually greater<br />
than 95% sugar and corn syrup solids, alternate confectionery products can even<br />
be made based on a consistent supply of solid rework.
Rework Laboratory Exercise<br />
This exercise will demonstrate the effect of four different processing parameters on<br />
the adsorptive efficiency of Activated Carbon using a precoated vacuum filter system.<br />
Because the samples must stir for at least 1 hour, you will be preparing samples for<br />
the group that follows your group, and will be filtering samples from the group that<br />
came before yours.<br />
Ingredients<br />
• Assorted Ground Hard Candy (Containing Assorted Flavors as well as FD&C<br />
Yellow 5, Yellow 6, Red 40, Blue 1 and Red 3)<br />
• Activated Carbon, Fine Grind<br />
• Diatomaceous Earth (Filter Aid)<br />
• <strong>Citric</strong> Acid<br />
Equipment<br />
• Buchner Funnel<br />
• Filter Flask<br />
• Grade No. 415 Coarse Filter Paper<br />
• pH Paper<br />
• Hot Plate with Stirrer (4)<br />
• Stir Bar (4)<br />
• 1 liter Beaker (8)<br />
Procedures<br />
• Rework Solution (already done)<br />
Dissolve 10 pounds of ASSORTED HARD CANDY REWORK in 10 pounds of<br />
WATER. This makes a 50% solution.<br />
• Sample Preparation<br />
(I) CONTROL<br />
Rework Solution 400g<br />
Activated Carbon 2g<br />
pH ~6<br />
Temperature Ambient<br />
Weigh REWORK SOLUTION into a flask, drop in a stir bar and<br />
set on stirrer. Weigh ACTIVATED CARBON into beaker. Add<br />
10g WATER and stir well. Combine the rework solution and the<br />
carbon slurry, recording time.<br />
(II) LOW pH<br />
Rework Solution 400g<br />
Activated Carbon 2g<br />
pH ~2 to 3<br />
Temperature Ambient<br />
Weigh REWORK SOLUTION into a flask, drop in stir bar and set<br />
on stirrer. Check the pH and sprinkle in CITRIC ACID to lower
the pH to between 2 and 3. Record final pH. Weigh ACTIVATED<br />
CARBON into beaker. Add 10g WATER and stir well. Combine<br />
the rework solution and the carbon slurry, recording time.<br />
(III) HIGH TEMPERATURE<br />
Rework Solution 400g<br />
Activated Carbon 2g<br />
pH ~6<br />
Temperature 180 F<br />
Weigh REWORK SOLUTION into a flask, drop in stir bar and set<br />
on stirrer, turning on heat. Weigh ACTIVATED CARBON into<br />
beaker. Add 10g WATER and stir well. Combine the rework<br />
solution and the carbon slurry, recording time.<br />
(IV) HIGH CARBON<br />
Rework Solution 400g<br />
Activated Carbon 10g<br />
pH ~6<br />
Temperature Ambient<br />
Weigh REWORK SOLUTION into a flask, drop in stir bar and set<br />
on stirrer. Weigh ACTIVATED CARBON into beaker. Add 10g<br />
WATER and stir well. Combine the rework solution and the<br />
carbon slurry, recording time.<br />
To keep things moving, we will try to space the samples 5 minutes apart. Therefore,<br />
when you are ready to add the carbon slurry, check when the person before you<br />
added their carbon slurry and leave as close to a 5 minute gap as possible.<br />
• Sample Filtration<br />
Set up the Buchner Funnel on the Filter Flask. Moisten a Filter Paper and<br />
place it in the Funnel. Slurry 75g of DIATOMACEOUS EARTH with 325g<br />
WATER. Turn on the vacuum and pour the diatomaceous slurry rapidly into<br />
the funnel. When the filter cake is firm, shut off the vacuum and pour-off the<br />
water from the Filter Flask. Replace the Funnel, turn the vacuum back on and<br />
rapidly pour the REWORK TEST SAMPLE into the Funnel onto the filter cake.<br />
Collect the permeate and label it.
NOTES and ASIDES<br />
When designing a rework system, begin with approximately 1 pound carbon for every<br />
100 pounds of rework solids. You may need more or less depending on the amount<br />
of undesirable <strong>com</strong>ponents present and the desired discoloration and blandness of<br />
the finished rework syrup.<br />
Different <strong>com</strong>ponents are adsorbed optimally under different conditions and at<br />
different rates. You may need to make adjustments to your process as the nature of<br />
your rework supply changes.<br />
Activated Carbon will cost you approximately $1 a pound while Filter Aid <strong>com</strong>es in at<br />
about one third of that. Factoring in labor, steam, electricity, equipment depreciation<br />
and possibly even sewage charges will let you determine whether your scrap is worth<br />
reworking with a liquid system.
CONTROL<br />
Rework Solution (from the 1 gal bottle) 400g (about 400 ml)<br />
Activated Carbon 2g<br />
pH ~6<br />
Temperature Ambient<br />
• Measure the REWORK SOLUTION into a 1 liter plastic<br />
beaker, drop in a stir bar and set on stirrer.<br />
• Weigh ACTIVATED CARBON into a small beaker. Add<br />
10g WATER and stir well.<br />
• Combine the rework solution and the carbon slurry,<br />
recording time.<br />
• DO NOT TURN ON THE HEAT!
LOW pH<br />
Rework Solution (from the 1 gal bottle) 400g (about 400 ml)<br />
Activated Carbon 2g<br />
pH ~2 to 3<br />
Temperature Ambient<br />
• Measure the REWORK SOLUTION into a 1 liter plastic<br />
beaker, drop in a stir bar and set on stirrer.<br />
• Check the pH and sprinkle in CITRIC ACID (only a pinch<br />
will do it) to lower the pH to between 2 and 3. Record final<br />
pH.<br />
• Weigh ACTIVATED CARBON into a small beaker. Add<br />
10g WATER and stir well.<br />
• Combine the rework solution and the carbon slurry,<br />
recording time.<br />
• DO NOT TURN ON THE HEAT!
HIGH TEMPERATURE<br />
Rework Solution (from the 1 gal bottle) 400g (about 400 ml)<br />
Activated Carbon 2g<br />
pH ~6<br />
Temperature 180 F<br />
• Measure the REWORK SOLUTION into a 1 liter GLASS<br />
beaker, drop in a stir bar and set on stirrer, and turning on<br />
heat<br />
• Weigh ACTIVATED CARBON into a small beaker. Add<br />
10g WATER and stir well.<br />
• Combine the rework solution and the carbon slurry,<br />
recording time.<br />
• TURN ON THE HEAT ONLY IF YOU USED A GLASS<br />
BEAKER!
HIGH CARBON<br />
Rework Solution (from the 1 gal bottle) 400g (about 400 ml)<br />
Activated Carbon 10g<br />
pH ~6<br />
Temperature Ambient<br />
• Measure the REWORK SOLUTION into a 1 liter plastic<br />
beaker, drop in a stir bar and set on stirrer.<br />
• Weigh ACTIVATED CARBON into a small beaker. Add<br />
10g WATER and stir well.<br />
• Combine the rework solution and the carbon slurry,<br />
recording time.<br />
• DO NOT TURN ON THE HEAT!
Hard Candy Flavor Considerations<br />
Presented by Paul Srnak<br />
The following considerations must be addressed when adopting a new flavor item,<br />
substituting for existing flavors in a given item, or modifying an existing item. Most of the<br />
discussion deals mainly with added flavors such as peppermint or citrus oils, and not with<br />
flavors contributed by value-added ingredients or reaction flavors. These topics are<br />
mentioned briefly at the end.<br />
• Cost. While Flavors are often only a small part of the cost of a hard confection, they<br />
can have substantial effect if you are dealing with small margins. Flavor costs can<br />
range from $2 per pound to 20 or more times that amount, especially when dealing<br />
with Natural Flavors.<br />
• Get to know your Flavor Supplier. Having a good relationship with your flavor<br />
supplier ensures that you have the assistance you need in determining what flavor is<br />
most appropriate for you specific application. A good flavor supplier will also provide<br />
you with consistent flavors when you need them.<br />
• Natural or Artificial? Decide what Market you are Targeting. Is your current Customer<br />
base into health food or premium products, or is it concerned mainly with cost? This<br />
will be invaluable for determining whether to choose Natural or Artificial Flavors.<br />
Generally speaking, you can expect to pay more for natural flavors, will get a less<br />
stable ingredient, and will need to use more due to a lower flavor impact. However,<br />
contrary to popular public perception, natural flavors do not usually contribute less<br />
“chemicals” to the diet. For example, there are about 500 to 600 chemicals responsible<br />
for the flavor of fresh strawberries and would therefore be present in a natural<br />
strawberry flavor. On the other hand, a good artificial strawberry flavor would only<br />
need about 15 to 20 of these same chemicals. So which one contributes more chemicals<br />
to the diet?<br />
• Stability. This also relates back to natural vs artificial flavors, but it includes other<br />
considerations. Without exception, hard candy flavors must withstand high<br />
temperatures. Flavors are usually incorporated into batches at temperatures in excess of<br />
250 F because the hard candy mass must still be pliable. Fortunately, once incorporated<br />
into the hard candy “glass”, the flavors are usually fairly well protected. Flavors must<br />
also be stable enough to resist changes over time, since a flavor with a short shelf-life<br />
would probably require more operator discrimination than it would be worth. Storage<br />
conditions can also affect flavor quality. Some flavors may keep well under<br />
refrigeration but degrade quickly at elevated temperatures, while others are best stored<br />
at room temperatures. The storage container can also affect product quality, but not<br />
simply due to the addition of off-flavors from the packaging material itself. For<br />
example, many of you may be familiar with the “sucked-in” and distorted plastic flavor<br />
bottle. In some cases, the plastic used to manufacture the storage container may be<br />
more permeable to certain chemical <strong>com</strong>ponents of the flavor than to other chemical
<strong>com</strong>ponents. Over time, this differential chemical permeation could result in the<br />
selective evaporation of some flavor <strong>com</strong>pounds and the resulting concentration of<br />
others. This will therefore covertly change the characteristics of your flavor. Also with<br />
some flavors, (especially citrus flavors), flavor <strong>com</strong>ponent oxidation can result if the<br />
storage container is permeable to oxygen. Finally, flavor <strong>com</strong>ponents can react with<br />
each other to produce off flavors. This is another reason to use knowledgeable flavor<br />
suppliers and to avoid mixing your own “custom” flavors (unless you have the<br />
expertise required).<br />
• Unwanted Attributes. Does the flavor contribute undesirable colors? When dealing<br />
with natural pastes or powders, does the flavor contribute gritty textures? Sometimes<br />
the method used to incorporate the flavor is critical in determining whether it will work<br />
or not. Obviously when dealing with a low-moisture system such as hard candy, a<br />
water-based flavor would be undesirable since it could make your product sticky,<br />
(furthermore, flavor <strong>com</strong>ponents often flash off with the water with these types of<br />
flavor systems).<br />
• Does the Flavor undergo Chemical Changes during Processing, or does it react with<br />
other Ingredients? The flavor should not change when it is exposed to the high<br />
processing temperatures found in hard candy production. The flavor must be relatively<br />
inert with regard to other candy ingredients. For example, if you have an acidulated<br />
candy, the flavor must not be pH sensitive. The flavor must not react with added colors<br />
either.<br />
• How will you incorporate the Flavor into the Candy? In a perfect world, you could add<br />
your flavor directly to your pre-cook. Unfortunately, this is rarely possible since the<br />
high cooking temperatures required, especially coupled with the use of vacuum, would<br />
quickly strip off flavors. However, there are several methods that are successfully used<br />
by hard candy manufacturers to incorporate flavors. For example, (a) modern highvolume<br />
lines normally use Direct Flavor Injection. With this method, the flavor is<br />
metered directly into the cooked hard candy mass as it travels through the discharge<br />
piping from the cooker. This allows for excellent control of the amount of flavor used<br />
(provided the equipment is well maintained), and helps to minimize flavor loss due to<br />
volatilization. Some type of in-line static mixer would be needed in this type of system.<br />
(b) Adding the flavor batchwise into the candy mass. This method is either done<br />
manually or by machine, and normally involves a considerable amount of volatilization<br />
since the candy mass is usually still quite hot at this point. The flavor can either be<br />
stirred in, poured across the candy mass as it sits on the cooling table (cooling to<br />
produce a surface crust, followed by pulverizing of this crust will give you a powdery<br />
surface to “mop up” the flavor), or it can be added at the puller. (c) Add the flavor with<br />
another ingredient. If the formula permits, mixing the flavor into a dry ingredient such<br />
as citric acid or salt will greatly simplify incorporation as well as reduce volatilization.<br />
However, the flavor must not react with the dry ingredient, nor must it hamper the<br />
incorporation of the dry ingredient (for example, due to lumping). When choosing a<br />
flavor, it is vital to take the production procedures into account. A flavor that works<br />
well in a direct injection system may prove lacking when mixed in batchwise. This
may be the result of flavor <strong>com</strong>ponents being “stripped off” due to differences in their<br />
volatilities.<br />
Finally, something must be said about value-added ingredients and reaction products.<br />
Value Added Ingredients such as honey, coffee, nuts, fats, dairy products etc. provide their<br />
own distinct flavors to hard candies as well as allowing the confections to demand higher<br />
prices. Unfortunately, these ingredients can vary from season to season and from supplier<br />
to supplier. Furthermore, the freshness of many value added ingredients is critical (this is<br />
especially true for nuts and dairy fats, since rancidity can quickly render the products<br />
unusable). These are ingredients where supplier integrity and inventory control are critical.<br />
Reaction Flavors are a different problem altogether. Caramel flavor is a classic reaction<br />
flavor. Caramel flavor is produced by the Maillard reaction between milk proteins and<br />
reducing sugars. Obviously, if either of these ingredients is absent (such as when working<br />
with sugar-free confections), or if ingredient concentrations are changed, (cutting back on<br />
milk ingredients to lower costs), then the final product flavor could change drastically.<br />
Changes in processing conditions can also affect reaction flavors. For example, changing<br />
hold times due to delays in processing or changing cook temperatures can quickly result in<br />
the over-production of reaction flavors. With these types of products, it is wise to stick to<br />
existing ingredients, formulations and processing procedures if you have a loyal customer<br />
base, or to substitute added standardized flavors and then to strive to minimize the<br />
production of reaction flavors during manufacture.
Hard Candy Color Considerations<br />
Presented by Paul Srnak<br />
As with flavors, there are several considerations that must be addressed when looking at<br />
hard candy coloring options. Again, most of this discussion will deal with high-intensity<br />
coloring <strong>com</strong>pounds, rather than with value-added ingredients that contribute color as a<br />
side-effect of their usage.<br />
• Cost. Colors normally give a tremendous “Bang for your Buck” due to their usage at<br />
only trace levels. This applies especially to synthetic FD&C dyes. For example, $1. 00<br />
worth of dry FD&C Yellow 5 dye will easily tint 2,500 pounds of hard candy with a<br />
bright pleasing yellow color.<br />
• Natural or Artificial? This decision is not as simple as with flavors, since the FDA<br />
does not allow use of the term “naturally colored” if the candy contains any colorants,<br />
regardless of origin. The only exception would be value-added ingredients that<br />
incidentally contribute color. “Certified” or “Non-Certified” colors would be more<br />
appropriate terms in this discussion. Certified colors are the seven <strong>com</strong>mon FD&C<br />
dyes (Red 40, Blue 1, etc.), while non-certified colors are all the other colorants,<br />
including nature-derived colors as well as caramel color and titanium dioxide.<br />
However, the Nutrition Labeling & Education Act (NLEA) did tilt the playing field<br />
slightly in favor of not using certified dyes due to labeling particulars, (see below). As<br />
with flavors, certified dyes are cheaper, often used in smaller quantities, are usually<br />
more stable, and are more consistent than nature-derived colors.<br />
• Color Labeling. The FDA basically requires that all ingredients used to provide a tint<br />
to hard candies be labeled as an added color, unless the ingredient adds this color<br />
incidentally. For example,<br />
(a) Molasses would provide a brown tint to hard candies, (along with a characteristic<br />
taste), but would not need to be labeled as a color.<br />
(b) Natural Red Beet Extract would provide color, but the candy could not be<br />
represented as “naturally colored”. It could be represented as “artificially colored”,<br />
“colored with natural red beet extract”, or red beet extract could just simply as be<br />
listed by name on the ingredient panel.<br />
(c) Due to NLEA requirements, FD&C Certified dyes must be listed by name, (e.g.<br />
Red 40, Blue 1, etc.).<br />
• Unwanted Attributes. Most hard candy colorants contribute nothing to the flavor and<br />
texture of hard candy predominately because they are used in such small quantities.<br />
Some of the nature-derived colorants could impart slight aftertastes. Of course, being<br />
implicated as allergens (Yellow 5) or as carcinogens (Red 3) could be viewed as<br />
unwanted attributes.<br />
• Stability. Not all hard candy colorants are created equally, and not all hard candy<br />
colorants behave the same under different conditions. Generally speaking, in hard<br />
candy applications you can expect the following:
Color Light Acid Heat<br />
Blue 1 Good Good Good<br />
Blue 2 Pathetic Pathetic Poor<br />
Red 3 Poor Pathetic Good<br />
Red 40 Very Good Good Good<br />
Yellow 5 Good Good Good<br />
Yellow 6 Moderate Good Good<br />
Green 3 rarely used due to cost<br />
Turmeric Poor Good Very Good<br />
Beta Carotene Good Very Good Good<br />
Annatto Fair Fair Good<br />
Caramine Excellent Good Very Good<br />
Red Beet Juice Fair Fair Poor<br />
A lack of light stability can be an insidious problem that expresses itself only after your<br />
product has reached the retailer or the consumer, so it is an issue you must take into<br />
account.<br />
• Does the Color Undergo Chemical Changes during Processing? This is definitely an<br />
area where the confectioner must exercise extreme caution, and it relates back to the<br />
stability of the colorants. Heat stability is critical because processing temperatures are<br />
high and acid stability is important because low pH’s are often present in fruit flavored<br />
candies. A good color supplier can help you work through formulation changes to<br />
avoid processing problems, while trial-and-error tests will immediately tell you<br />
whether it will or won’t work.<br />
• How will you incorporate the colorant into your product? Ideally, your system will<br />
allow you to add as-is colorants directly into a large volume of pre-cook syrup. This<br />
will give you the most uniform batches at the lowest possible cost. This method does<br />
have some drawbacks. Due to the high coloring ability of most food dyes, extremely<br />
low concentrations of colors are needed. This often requires an unreasonably minute<br />
quantity of color that would be difficult to measure out accurately. Because FD&C<br />
dyes must be in solution to provide tincture, there must also be sufficient water present<br />
to thoroughly dissolve the colors. Fortunately, color suppliers have <strong>com</strong>e up with<br />
several ingenious methods for incorporating colors into hard candy. For example,<br />
(a) Liquid Colors. This applies mainly to certified dyes. Color suppliers can produce<br />
color concentrates (that require dilution or mixing before use), or ready to use<br />
solutions. A confectioner can also make their own custom color solutions using the<br />
dry dyes. Often, propylene glycol or glycerin is added as a solution preservative or<br />
as a co-solvent. Liquid colors can be added to pre-cooks or directly to the cooked<br />
candy mass. Use control is excellent.<br />
(b) Color Pastes. These are often solutions of dyes bulked up with a powder such as<br />
dextrose. Pastes are usually added to individual batches of the cooked candy mass.<br />
Use control is low.
(c) Color Cubes. Similar to pastes, cubes often incorporate a hard fat as an ingredient<br />
so that they are solid at room temperature. Cubes melt easily in the hot hard candy<br />
but often require pounding to speed up the mixing process. Color cubes are<br />
produced by slabing out and scoring the color mass. Use control is good.<br />
(d) Color Granules. Basically, ground-up color cubes. Often harder fats are used to<br />
keep the finished granules from sticking together. Granules melt faster due to their<br />
smaller particle size and are easier to use than cubes. Use control is good if there is<br />
a uniform particle size.<br />
• What Colors are best for Hard Candies? This all depends on what you are trying to<br />
ac<strong>com</strong>plish. Color Lakes will work well for striping or with products that require a<br />
painted, non-opaque appearance. Titanium dioxide can be used to lighten candy masses<br />
that are too dark due to processing problems, or as a substitute for pulling. Certified<br />
dyes are easy to use but it may be difficult to produce deep colors such as black.<br />
Finally, nature-derived colors may produce attractive shades but they are often quirky<br />
and some have questionable kosher status.
Boiling Under Vacuum<br />
Presented by Paul Srnak<br />
Boiling under vacuum facilitates the achievement of a high solids level at a relatively low<br />
temperature. This reduces inversion and caramelization of the sugar and reduces the syrup<br />
temperature for subsequent processing.<br />
Approximate Atmospheric Vacuum Boiling Vacuum<br />
% Solids Temperature Temperature in/Hg<br />
F C F C<br />
96 289 143 264 129 25<br />
97 302 150 275 135 27<br />
98 320 160 286 141 28<br />
It is not necessary for the whole boiling cycle to be under vacuum. Normally, syrup will be<br />
boiled to ~266 F (130 C) and then subjected to a vacuum of 28 in/Hg for ~6 minutes for a<br />
final solids of >98%<br />
When caramel is subjected to vacuum, the purpose is usually to rapidly reduce its<br />
temperature.
Traditional Test for Syrup Boils<br />
Approximate Temperature<br />
Term F C Texture<br />
Thread 230-235 110-113 Forms a thread between thumb and index<br />
finger<br />
Soft Ball 237-244 114-118 Dip a spatula into the batch and remove<br />
the sample in cold water. Sample will form<br />
a soft ball when cool.<br />
Firm Ball 250-255 121-124 Sample will form a firm ball<br />
Hard Ball 259-264 126-129 Sample will form a hard ball<br />
First Crack 264-270 129-132 Dip a spatula into the batch and remove<br />
the sample in cold water. Press into a thin<br />
sheet. Flick the sample with the index<br />
finger. It will crack if thoroughly cool<br />
2 nd Crack 275-280 135-138 Dip a spatula into the batch and remove<br />
the sample in cold water. Press into a thin<br />
sheet. When thoroughly cool, it will break<br />
and not bend.<br />
Hard Crack 284-310 140-154 The cooled spatula sample will shatter<br />
like glass<br />
Caramel 335-350 168-177 Sample is brown and will quickly set like<br />
glass.
HARD CANDY: (Srnak)<br />
Answer Key:<br />
GRAINED MINTS<br />
1) What is the purpose of the Cream of Tartar? Cream of Tartar is a<br />
“Doctor” used to increase the Inversion of the Sucrose. Without the<br />
resultant Glucose and Fructose, the candy mass would grain, or<br />
crystallize, uncontrollably.<br />
2) Since it is essentially all cooked-off, what effect could the water quality<br />
have on the product? Substances such as minerals in the water may<br />
inhibit or greatly enhance the function of the “Doctor” (depending on<br />
what is present). That is why formulas must be tailored to the specific<br />
region where the candy is being made.<br />
3) Why are the sides washed down with Water? The Sugar must be<br />
totally dissolved when there is enough water present to ac<strong>com</strong>plish<br />
the job (early in the cook). Otherwise, any crystalline sugar crusted<br />
along the water line can act as a “seed” to cause uncontrolled<br />
graining.<br />
4) Why is the Powdered Sugar added at the puller? To act as a “seed”<br />
so that you get controlled crystallization when the batch is ready. The<br />
Powdered Sugar introduces numerous small nuclei for crystal growth,<br />
which results in lots of fine crystals (and a smooth texture) rather than<br />
a few large crystals (and a gritty texture).<br />
FILLED PILLOWS<br />
1) Can a water-based (jelly) filling be honey<strong>com</strong>bed? No. The final<br />
product consists of thin layers of hard candy alternated with fatbased<br />
filling. A water-based filling would soften or dissolve this thin<br />
layers destroying the desired texture.<br />
2) Why is the filling heated? If the filling is cold, it will cool the inside<br />
candy surface that it is contact with causing it to be<strong>com</strong>e inflexible.<br />
Forming and/or leaking problems will result.<br />
CUT ROCK<br />
1) Why is such a low Cook Temperature used? This is a “Demo” lab. To<br />
give enough work time with a small batch under less than ideal<br />
conditions, higher residual moisture is desired. Shelf-life would be<br />
unacceptably short for retail sale under these conditions.<br />
2) Why is the candy roped-out on a hot table? Surface cooling would<br />
reduce or eliminate the elasticity of the candy. It would not rope-out to<br />
the desired diameter smoothly…try it with the demo sample.
Hard Candy Demonstration<br />
Grained Mints<br />
Ingredients<br />
Sugar 25 lbs<br />
Water 9 lbs<br />
Vegetable Shortening 5 oz<br />
Cream of Tartar 10 grams<br />
Peppermint Oil (or other flavor) ¾ oz<br />
Glycerin 2 oz<br />
Powdered Sugar 4 oz<br />
Additional Powdered Sugar for Storage Trays<br />
Procedure<br />
• Place Sugar, Water, Shortening and Cream of Tartar into a clean kettle and place<br />
the kettle on the gas-fired Savage Cooker.<br />
• As the batch begins to boil, wash down the sides of the kettle with a small amount of<br />
water using a brush or a wet rag.<br />
• Cook the batch to 280 F.<br />
• Pour the batch onto an oiled cooling table and allow it to cool with a minimum of<br />
agitation.<br />
• Load the batch onto a pulling machine and pull it for 1½ to 2½ minutes. While<br />
pulling add the Peppermint, the Glycerin and the Powdered Sugar.<br />
• Remove the batch from the puller and shape it into a roll.<br />
• Spin and cut the roll in 2 to 3 foot sections of “rope” and place the “rope” onto trays<br />
dusted with Powdered Sugar.<br />
• Store the trays in a warm, humid area to allow it to grain overnight.<br />
Be sure to sample the candy before it has had a chance to mature and note the texture.<br />
Questions<br />
1) What is the purpose of the Cream of Tartar?<br />
2) Since it is essentially all cooked-off, what effect could the water quality<br />
have on the product?<br />
3) Why are the sides washed down with Water?<br />
4) Why is the Powdered Sugar added at the puller?
Hard Candy Demonstration<br />
Filled Pillows<br />
Ingredients<br />
Filling Portion<br />
Vegetable Shortening 5 lbs<br />
Powdered Sugar 10 lbs<br />
Flavor ¼ oz<br />
Candy Portion<br />
Sugar 25 lbs<br />
Corn Syrup (42 DE) 25 lbs<br />
Water 8 lbs<br />
Flavor & Color as needed<br />
Release Agent as needed<br />
Procedure<br />
• Place the Powdered Sugar, Shortening and Flavor into a steam kettle and heat it<br />
slowly to 170 - 180 F. Hold the filling at this temperature until it is needed. (The<br />
Filling should have a sufficient amount of Powdered Sugar in it to make it firm<br />
enough to stand up).<br />
• Cook the Sugar-Corn Syrup mixture to 280 F in an open gas-fired Savage kettle.<br />
• Spray the vacuum kettle with release agent (top and bottom) and transfer the hot<br />
batch to it. Close the cover and draw a vacuum for about 4 minutes.<br />
• Discharge the cooked candy into a kettle that has also been sprayed with release<br />
agent.<br />
• Remove a baseball-sized portion to be used as “shine”. Hold it on the hot table<br />
under a blanket.<br />
• Flavor and color the cooked candy in the kettle.<br />
• Pour the candy batch onto the cold table and cool it to a working temperature.<br />
• Place the cooled batch on the puller and pull it until it is satin.<br />
• Remove 1/3 of the batch and place it on the hot table. This will be used for the<br />
“jacket” of both sample batches.<br />
• Flatten the remainder of the batch and place the Filling on it.<br />
• Wet the outside edges of the batch with water and, forming an envelope, wrap and<br />
seal the batch around the filling.<br />
• Divide this envelope in two (for two sample batches).<br />
• Wrap one filled envelope in a jacket, shape it into a roll, and spin it through the<br />
pillow machine. These are the Filled Pillows.<br />
• Fold and stretch (honey<strong>com</strong>b) the remaining filled envelope.<br />
• Wrap the remaining jacket around this portion, shape it into a roll, and spin it<br />
through the pillow machine. These are the Honey<strong>com</strong>bed Pillows.<br />
Questions<br />
1) Can a water-based (jelly) filling be honey<strong>com</strong>bed?<br />
2) Why is the filling heated?<br />
7/25/01. Use Savage agitated cooker to make the batch for the pillows. Cooked<br />
2 pails blend to 275 F in
Hard Candy Demonstration<br />
Cut Rock<br />
Ingredients<br />
Sugar 25 lbs<br />
Corn Syrup (42 DE) 25 lbs<br />
Water 8 lbs<br />
Flavor & Color as needed<br />
Release Agent as needed<br />
Procedure<br />
• Imagine a design and determine how you will make it.<br />
• Cook the Sugar-Corn Syrup mixture to 275 F – 280 F in an open gas-fired Savage<br />
kettle.<br />
• Spray the vacuum kettle with release agent (top and bottom) and transfer the hot<br />
batch to it. Close the cover and draw a vacuum for about 4 minutes.<br />
• Discharge the cooked candy into a kettle that has also been sprayed with release<br />
agent.<br />
• Divide up the cooked candy into portions sufficiently large enough for each<br />
<strong>com</strong>ponent, leaving the largest part for the background.<br />
• Flavor and color the background portion. Color all the <strong>com</strong>ponents (flavoring them<br />
will only be necessary if they make up an excessive percentage of the total product.<br />
Otherwise, flavoring the background is usually sufficient).<br />
• Kneed the various portions on the cold table to cool them to working temperatures.<br />
• Depending on the design, portions may be pulled. Avoid excessive pulling since it<br />
may make the candy too spongy to handle properly.<br />
• Form the <strong>com</strong>ponents (more hands = better) on the hot table. When <strong>com</strong>ponent<br />
shapes are <strong>com</strong>pleted, surface-cool them on the cold table to form a stabilizing crust<br />
of hardened candy. Transfer them back to the hot table to avoid excessive cooling.<br />
Keep forming them to avoid unwanted deformation.<br />
• Assemble the various <strong>com</strong>ponents. Use water to glue them together.<br />
• Spin out the batch on the hot table. Traditional Cut Rock is roped-out, allowed to<br />
cool on a long, straight conveyor, and then struck with a sharp edge to split off<br />
button-shaped cross-sections. In lieu of such equipment, hand roll sections of rope<br />
on the cold table and strike them with a spatula to cleave off buttons.<br />
Questions<br />
1) Why is such a low Cook Temperature used?<br />
2) Why is the candy roped-out on a hot table?