Aerated Cheese Chocolate

Final Project Report 14th October 2016

Chocolate Innovation

FOSC 311 Department of Food Science University of Otago

Victoria Purdy Hannah Little Sakinah Hussaini Renuka Reddy

Executive Summary The project purpose was to incorporate bacteria into chocolate and to then enable it to survive. The development process started with making chocolate from scratch but was unsuccessful so commercial chocolate was used. Whittaker’s chocolate was chosen as it was of a higher quality than Cadbury’s. Bacteria was then added chocolate but it did not reproduce and began to die off. Freeze dried cheese and cheese flavours were added to chocolate and the group decided to use the freeze dried cheese. The flavour of chocolate then needed to be determined, the group chose Whittaker’s 50% cocoa solid chocolate. Next, the percentage of blue vein that would be added to the chocolate was determined to be 10%. Finally, the group decided to set the chocolate in an aerated form rather than regular chocolate. The target market for the product was identified as people aged over 18. The consumer acceptance study was held on campus in the Gregory Building of the University of Otago where 95 people participated in the study. The remaining 35 participants were recruited off campus. Participants indicated their hedonic rating of the Aerated Cheese Chocolate on an unstructured line scale. They then indicated the intensity of the cheese and chocolate flavours. Finally, they compared the texture of the prototype with the texture of Cadbury’s Bubbly chocolate. The prototype earned a hedonic rating of 103 out of 150 in the consumer acceptance study. Results showed that a majority of participants thought there was too little cheese and therefore, a stronger flavour may be developed. During the shelf life trial the parameters measured were the microbial numbers, colour, water activity, lipid oxidation and texture at both 4 °C and 25 °C. The results from the shelf life trial showed that the product remained safe for consumption over the 6 week period but further testing will be needed to be done to confirm the exact shelf life. The original brief of incorporating bacteria into chocolate and enabling them to survive was found to be too unrealistic for the group to achieve. Our final decision for the prototype was to use cheese flavours to imitate the flavours bacteria produce. It was set in an aerated form so that this would mimic holes bacteria would produce, like those in cheddar cheese. There is still work to be done regarding the final composition of the product including determining the ultimate blue vein percentage and the guaranteed shelf life. The team thought it would be a good idea to introduce a range of chocolates that vary from very weak (2.5%) to very strong (20%). Another consumer trial would need be run to ensure that consumers are satisfied by this. Table of Contents

1.0 Introduction ...... 1 1.1 Participants ...... 1 1.2 Project Goals and Challenges ...... 2 2.0 Summary of Development Stages ...... 2 3.0 Summary of Outcomes ...... 5 3.1 Selected Concepts ...... 5 3.2 Recipes, Raw Materials, Formulation and process ...... 7 3.3 Product Safety ...... 9 3.4 Shelf life stability ...... 10 3.5 Food Regulatory Compliance ...... 18 3.6 Consumer Acceptance ...... 19 3.7 Costing and Marketing ...... 25 4.0 Specifications...... 27 4.1 Final formulations/processing instructions/quality criteria/process yields and costings...... 27 4.2 Nutritional information (NIP) and if relevant nutritional claims/ health claims ...... 30 4.3 packaging design and specifications ...... 32 5.0 Project conclusion and recommendations ...... 36 6.0 References ...... 38 7.0 Appendices ...... 41 7.1 Appendix A – Project Brief ...... 41 7.2 Appendix B – Project Plan ...... 42 7.3 Appendix C – Idea Generation List ...... 44 7.4 Appendix D – Consumer market research summary ...... 45 7.5 Appendix E - Bill of Materials ...... 46 7.6 Appendix F - HACCP Summary Table ...... 46 7.7 Appendix G - Consumer Acceptance Test Ballot Form and Statistical Summary Tables ...... 47 ...... 48 7.8 Appendix H - Product Costings ...... 54 7.9 Appendix I - Shelf Life Stattistical Analysis ...... 55 7.10 Appendix J – Raw Materials ...... 60 7.11 Appendix K – Total Expenditure ...... 61

1.0 Introduction Chocolate innovation is sponsored by Giapo Grazioli, who owns Giapo Haute Ice cream, located on Queen Street in Central Auckland. Giapo Haute Ice Cream is a very successful ice-cream shop that creates very innovative ice cream creations. The company opened in 2009, and since then, the company has managed to grow and concentrate more on innovative product delivery and sensory experiences for the consumers (Giapo. 2014). Giapo, and his Ice cream shop together, have won many awards over the 7 years it has been open.

The project brief (7.1), set by Giapo Grazioli, was set to develop a novel chocolate that included live bacteria. If chocolate innovation were successful in the project brief, it would be of huge benefit to Mr Grazioli as there is no chocolate with live bacteria on the market today. Mr Grazioli would be able to sell this chocolate or incorporate it in his ice cream creations made in his shop, Giapo Haute Ice cream, if the bacteria grown in the chocolate were deemed safe to consume. Alongside this, Mr Grazioli would be able to publish the findings in a scientific journal. Therefore, the project benefits Giapo Grazioli as he would be the face of this new chocolate concept and be able to add it to his wonderful creations he already makes, growing his business in a different direction.

1.1 Participants Team Members Victoria Purdy - Team Leader Studying: Bachelor of Science, major: Food Science/ minor: Chemistry

Hannah Little - Formulation and Shelf life Manager Studying: Bachelor of Science, major: Food Science/ minor: Psychology

Sakinah Hussaini - Consumer Testing Adviser Studying: Bachelor of Science - Food Science

Renuka Reddy - HACCP Manager Studying: Diploma for Graduates - Food Science

1

Supervisor s Phil Bremer Tobi Richter Professor Ph.D. Student Email: [email protected] Email: [email protected] Phone:03 479 5469

Sponsor Giapo Grazioli Address: 278 Queen St, Phone: 09 550 3677 Auckland 1010

1.2 Project Goals and Challenges The original project goals set out to achieve by the team were: ● To create a novel chocolate with live bacteria. ● Carry out multiple experiments to gain more knowledge about bacteria and chocolate technology. ● Successfully attract a new target market of chocolate consumers

The project brief was very challenging as chocolate has a low water activity (~0.4aw) and bacteria enjoy environments with a higher water activity (generally ≥ 0.6aw). Multiple experiments were carried out to gain knowledge on what was possible to achieve in terms of the brief. From these experiments, a new project goal was made; to successfully develop an innovative chocolate product that is not on currently on the market. All of these experiments with bacteria led to the development of many different product concepts, including our final product, mixing blue vein cheese with dark chocolate. Chocolate innovation went through a lot of development stages during all of the experiments. These development stages finally led to the final product, Aerated Cheese Chocolate.

2 2.0 Summary of Development Stages

Product development began with trying to find which bacteria would grow in chocolate. The group carried out a literature review during the first three weeks of March and had no success with finding a suitable bacterial strain, so by the end of march the experimental part began. Probiotic and lactic acid bacteria were added to chocolate, lactic acid bacteria was grown in milk and cheese was made using Lewis Road Creamery’s Chocolate Milk to see if that was a viable option. These experiments were carried over a five weeks period, which ended on the 29th of April. However, the experiments with bacteria were ultimately unsuccessful. Additionally, the focus group which was conducted on the 16th of May, revealed that consumers did not like the idea of a probiotic chocolate. Therefore, on the 23rd of May, the team decided to go ahead and add cheese to chocolate as this would imitate the flavours that bacteria would produce if they continued to grow in the chocolate. From the team's final decisions, a go/no go chart was created, as illustrated in figure 1.

2

Figure 1. Go/no go diagram used to decide final prototype.

The process began by deciding whether to make chocolate or use commercially available chocolate. The decision was made that the group would use commercially available chocolate as it was better quality than what chocolate innovation could make from scratch. Next, the brand and flavour chocolate had to be decided. Upon benchmarking and tasting Cadburys, Whittaker’s and Lindt Chocolate, on 25th of May, the team decided that Whitaker’s 50% cocoa dark chocolate was the best fit to use as a raw material for our product. Trials were then run to choose which type of cheese paired best with Whittaker’s 50% cocoa dark chocolate. Different cheese

3 flavours and freeze dried cheeses were added to the chocolate. It was found that the cheese flavours were noted to have a ‘fake flavour’ and that the freeze dried cheeses were more popular. Therefore, on the 3rd of June Waimata Blue vein cheese was chosen. Trials experimenting with different strengths of cheese within the chocolate (2.5% ,5%, 10% & 15%) were carried out. The vacuum was also used to produce aerated chocolates. On the 28th of July, the final outcome of the go/no go trials was achieved, a product that was made of Whittaker’s 50% cocoa dark chocolate, with 10% freeze dried blue vein cheese and is set in an aerated formation. To verify the life of the new product, shelf- life testing was conducted from 9th of August to 15th of September (results discussed in section 3.5). Finally to gain insight into the opinions consumers would have for our new product, a consumer acceptance study was done on 20th of September (results discussed in section 3.6). The conclusions from the go/no go decisions did not fit the brief directly as bacterial cultures were not added to chocolate. However, there are microorganisms in blue vein cheese, such as penicillium roqueforti and lactic acid bacteria. On the other hand, the product concept is a very innovative idea and had many people wondering what it is and wanting to know more about it. When people were first approached with the product, they were confused by it, however often they enjoy it a lot more than they expected to. The products original name, Bubbly Cheese Chocolate, was not appealing to the consumers and therefore it was changed to Aerated Cheese Chocolate to make it more appealing. Illustrated below in figure 2 is a brief timeline of our prototype development throughout the year.

Figure 2. Brief timeline of Chocolate Innovation’s product development.

4

As discussed above, the most challenging aspect of the project was to enable the bacteria to survive in the chocolate. However, upon research it became obvious that this was going to be near impossible. This issue was overcome by altering the aim so that a uniquely flavoured chocolate could be created. In order to do this, cheese was added to chocolate as it would mimic bacterial flavours. Shelf life testing results showed that chocolate blooming had occurred over the six weeks period. In future proper tempering techniques and good manufacturing practices should be used to avoid fat and sugar blooming. Additionally more research can be done in the future in order to find a suitable bacterial strain that can survive in chocolate.

3.0 Summary of Outcomes

3.1 Selected Concepts Many ideas were generated (refer to idea generation list – 7.3) to attempt to fulfil the project brief. The final ideas were shortlisted to the following: ● Probiotic bacteria in chocolate ● Lactic acid bacteria in chocolate ● Growing lactic acid in milk and adding this to chocolate ● Cheese in chocolate

It was found during multiple experiments that bacteria would not survive in chocolate. Therefore, the first three ideas generated were not feasible. As a result, the concept of cheese being added to chocolate was developed.

Research shows that people begin to enjoy blue vein cheese at the age of 22 years (Associated Newspapers Ltd. 2015). This is associated with a decline in the number of taste buds we have as we age. Based on this information, the target market was originally defined as those aged 22 and over. Information gathered in the consumer acceptance test, found that people younger than 22 enjoyed our product. Thus the target market was redefined as people aged 18 and over.

5 Market research was conducted to determine what chocolate products were out on the market and what appeals to consumers. Research showed that Chocolate Innovation’s Aerated Cheese Chocolate had huge potential as cheese flavoured chocolate is described as a very novel product that is not currently available in the market and therefore has no current competitors. The choice to use dark chocolate, was decided due to information gathered during a focus group held in May. There was also pairings of the flavour with different cheeses on other occasions.

Manufacturing is not difficult for the product. From research, it has been noted that if the product reaches a commercial scale, manufacturing will become easier with larger equipment available, tempering will be easier to control and the process yield will increase.

As the product uses high quality products, the final product will be marketed as a luxury product and is likely to have a reasonably high cost (For more information on cost see section 3.7).

6

3.2 Recipes, Raw Materials, Formulation and process There were many formulation trials carried out in order to create the perfect prototype. Early in the formulation trials, the team experimented with making chocolate from scratch. However, the consistency was more like fudge, the texture was grainy and it left greasy residue in the mouth. Based on several failed attempts, the group decided to go ahead and purchase commercially available chocolate to use. From this stage onwards, the recipe formulation consisted of determining what percentage of blue vein cheese would be added to the chocolate and what flavour of chocolate would be used. Cadburys, Whittakers and Lindt Chocolate were purchased to determine whether they would be a good fit to use as raw materials. Upon tasting these products and assessing which one held the freeze dried blue vein cheese best, it was concluded that Whittakers would be used. Table 1 shows the information Canstar Blue (2016) collected on the overall satisfaction, taste, value for money, variety & range and packaging of several well known chocolate brands available in NZ.

Table 1 . Customer Satisfaction Ratings of Chocolate Brands in New Zealand (Canstar Blue, 2016)

As seen in table 1, Whittaker’s scored 5 stars for overall satisfaction, taste, value for money, variety and packaging. Therefore Whittaker’s is perceived as a high quality New Zealand product. For this reason, the team thought it was only fitting to pair this with Waimata Traditional Blue Vein Cheese as it is also high quality New Zealand product. Once the brands for the raw ingredients were decided, the flavour and cocoa percentage of the Whittaker’s chocolate that was to be used needed to be determined. Freeze dried blue cheese was

7 added to white chocolate, milk chocolate and dark 50%, 62% and 72% chocolate. It was decided that Whittaker’s 50% Dark Block would be used as it was not too bitter and complemented the cheese flavour the best. The next trial experimented with different amounts of blue vein cheese in the chocolate, including 2.5, 5, 10 and 15 percent. We chose to go with 10% as the cheese flavour was not too strong but there was a subtle hint. Another formulation trial was carried out to compare aerated chocolate with regular chocolate. We found that aerated chocolate was preferred within the group and around the lab as it was less grainy and ‘melted in your mouth’. Artificial blue vein cheese flavours was compared with freeze dried blue vein cheese. The group felt there was little difference in terms of the flavour so we chose to use the blue vein cheese as it meant there would be less artificial colouring and flavours.

The key outcome from the formulation trials (and therefore our recipe) was that we would use dark chocolate (50% cocoa) with 10% freeze dried blue vein cheese powder and create an aerated texture.

The Whittaker’s 50% Dark Chocolate provides a base ingredient for the cheese to be added to. The chocolate contains 50% cocoa solids, with dark rich flavour and well-rounded smoothness dairy free. The Waimata Blue Vein Cheese is added purely for flavour. Blue vein cheese contains cow’s milk, Penicillium Roquefort, it has a smooth, buttery texture. Blue vein cheese is known to have a bold, sharp and tangy flavour. The flavour is dominated by a compound called n-methyl ketones (alkan-2-ones). Penicilium roqueforti converts fatty acids to n-methyl ketones which contribute to the pungent flavour of blue cheese. (Lawlor, et al., 2003). The combination of chocolate with the blue vein cheese results in a unique sweet flavour with a hint of savoury.

The ingredients mentioned above are sourced from the supermarket, so if this product goes to market the company would easily be able to continue to source these ingredients. It was suggested that the chocolate should be brought from Bidvest at a wholesale price, however it was less convenient than buying it from the supermarket. Costings of the packaging and ingredients will be discussed in section 3.7. The yields and methods of the process are found in section 4.0.

8

There were a few technical issues when making the chocolates, the most concerning of which was the chocolate forming bloom. There are two different types of bloom that can occur in chocolate, sugar and fat bloom. Bloom is a white layer of fat or sugar that forms on the surface of the product. Fat bloom is likely to alter the texture of the chocolate from what it was when it was originally set (Amano Artisan Chocolate, 2016). Sugar bloom occurs when water comes into contact with the chocolate. The water dissolves the sugar on the surface of the product, which then crystallises and leaves a white residue (Amano Artisan Chocolate, 2016). Sugar bloom can occur when the chocolate is left in a humid room or when it is refrigerated and then placed in a warmer room, water will condense and cause bloom to form (Amano Artisan Chocolate, 2016). Fat bloom is more complex than sugar bloom and it is therefore harder to find the source of the problem. When the chocolate sets, it is essential that stable fat crystals form so that bloom does not occur (Amano Artisan Chocolate, 2016). The stable crystals are called Beta crystals, which are slightly smaller than alpha or Beta prime crystals, so the chocolate contracts, these newly formed crystals rise to the surface and form fat bloom. (Amano Artisan Chocolate, 2016). Factors that cause fat blooming are poor tempering, attempting to mix incompatible fats, disrupted cooling methods, temperature fluctuations and storage conditions. In the future it is imperative to ensure that careful tempering is used to avoid incorrect crystalline structures forming. The room the chocolate is set in should not be too warm to ensure undisrupted setting and cooling is achieved. The chocolate moulds must also be clean before the chocolate is poured into them to ensure that there is no left over fat to initiate blooming. Another issue was that the chocolates were sinking in the middle while they were setting in the vacuum, this was thought to be due to a leak in the vacuum and has since been fixed.

3.3 Product Safety A hazard analysis critical control point (HACCP) plan for the Aerated Cheese Chocolate was made to ensure that the final product is safe for consumption. The food safety objectives were to prevent the growth of bacteria by producing a product with water activity below 0.6 using a water activity meter and to produce a product free of metal fragments using a metal detector.

9 Most of the control measures in the processing steps were identified as quality control points (QCP). However, three critical control points were identified and methods were set out to regulate them. The first critical control point (CCP) is the intake of raw materials, a certificate of quality assurance must be obtained from the supplier. The second CCP is the water activity. When the cheese is ground into powder and also when the cheese powder is blended with the chocolate, it is important to ensure that the water activity is below 0.6 to prevent microbial growth and bloom from occurring. The third CCP is metal detection, the samples need to be passed through a metal detector to ensure that they are free of metal fragments. (Refer to the HACCP summary table in Appendix).

3.4 Shelf life stability Shelf life testing was conducted over a 6 week period from the 9th of August to the 15th of September. Over this time microbial numbers, colour, water activity, lipid oxidation and texture were all measured to identify how long the shelf life would be of the product. The chocolate samples were kept in vacuum sealed packages, half stored in a fridge at 4 °C and the other half stored in a 25 °C incubator.

Microbial Numbers The chocolate samples were prepared for plating using 0.1% peptone and stomacher bags to break up the sample. DBRC plates were used for the plating of the chocolate samples. After the plating techniques were complete, the plates were left in an incubator for one week and the microbial numbers were counted. The average amount of colony forming units (CFU) per mL for week zero was 1.42x106 CFU/mL, this decreased over the six week period to 1.5x104 CFU/mL (Table 1).

Table 2. Microbial Count Results Time Point 1 (week 0) Time 2 (week 6) Number of Viable Cells 1.42x10 6 ± 4.6x10 5 1.5x10 4 ± 8.0x10 3 (CFU/mL)

10 As shown in table 1 the amount of viable cells in week 0 was much larger than the amount present in week 6. One possible reason for this is that the hyphae present in week 0, were able to grow on the plate so they were counted within the ‘viable cell’ count. By the time it was week 6, only the spores would have been able to survive in the chocolate and therefore, only they would have been able to grow on the plate, hence the low plate count. Both the amounts illustrated in table 1 above are within the legal limits of penicillium allowed in food so there was no risk for the product becoming unstable during the 6 week shelf test in terms of microbial activity.

Colour A hunter colorimeter was used to measure the colour during the six week shelf life test. This measured the L, a and b values for both the 4 °C and 25 °C samples. The L value indicated the difference in lightness and darkness, specifically that a positive value is a lighter product and a negative value is a darker product (Konica Minolta Sensing. 2016). The a* value indicated a difference in red and green, a positive value means the product is redder and a negative value indicates the product is greener (Konica Minolta Sensing. 2016). The b* value indicated the difference in yellow and blue, specifically a more positive value indicates a yellow product and a negative value indicates a bluer product (Konica Minolta Sensing. 2016). These results were collected every two weeks for 6 week. Figure# illustrates the results from the colour tests over the six week period.

Figure 3. Colour measurements for 4 °C samples.

11

Figure 4. Colour measurements for 4 °C samples

The results illustrated in figure 3 and 4 were further analysed using ANOVA (7.9). This illustrated that the colour did not have any significant changes except for the a value for the 4 °C samples as the p value was found to be less than 0.05 (p-value = 0.049). Another significant change found in the colour was for the L value on the 25 °C sample (p-value = 0.040).

Overall, the L* value increased over time, indicating that the product became lighter over the 6 week period. The a* value decreased over time, indicating that the product became greener over the 6 week period. Only two of the L*a*b* values for the two samples varied and therefore, this does not present significant concern to the product during the 6 week period.

Water Activity Water Activity was measured every second week over the 6 week testing period. This was conducted by cutting the samples into small pieces and placed in the water activity meter one at a time, measuring a total of 3 samples for each temperature. The results were analysed using ANOVA tests, which are presented in tables # and #.

12 Table 3. ANOVA results for Water Activity 4 °C Samples

Table 3 shows that the difference water activity for the 4 °C sample over the six week period was not significant as the p-value was more than 0.05 (p-value, 0.16, 2sf).

Table 4. ANOVA results for Water Activity for 25 °C Samples

Table 4 shows that the difference water activity for the 25 °C sample over the six week period was significant as the p-value was less than 0.05 (p-value, 0.0031, 2sf).

The water activity needed to remain below 0.4 aw over the 6 week period in order for the product to remain stable. The average water activity taken each week remained below 0.4 aw. Table 9 shows that the water activity for the 25 degree sample varied significantly over the 6 week period, however it remained below 0.4 aw so it is not of concern for the product.

13 Lipid Oxidation Peroxide value (PV) is a measure of the amount of peroxides and hydroperoxides formed in the early stages of lipid oxidation. Autoxidation is a free radical reaction involving oxygen that leads to spoilage of fat and causes off-flavours. PV helps to indicate the extent of spoiled fat present and it is dependent on temperature, time and light (Kaleem et al, 2005). The method used to measure PV in this experiment was iodometric titration which is based on the oxidation of the iodide ion by hydroperoxides (ROOH) to determine the peroxide value. The method used in the present study used a saturated solution of potassium iodide, which was added to the extracted fat from the chocolate samples to react with hydroperoxides. It was then titrated with sodium thiosulfate and starch as an indicator.

The average peroxide value of the chocolate samples stored at 25 °C in week zero was 0.2554 mEq Kg -1 and increased to 0.2775 mEq Kg -1 in week 6. The values are very small which means lipid oxidation may not be a big concern for the product and can remain stable over a long time. As a general rule, PV should not be above 10 mEq Kg-1 fat to avoid rancid flavour. (Connell, 1975 as cited in Kilcast & Subramaniam, 2011). The samples were vacuum packed in foil and this meant that limited oxygen was available to interact which could have led to the low values of PV.

Figure 5. Bar graph of the peroxide values versus time for the chocolates stored at 25 °C.

Figure 5 illustrates that the lipid oxidation of chocolates stored at 25 °C had the greatest PV in week 3 which reflects the total concentration of peroxides and hydroperoxides present at that

14 time. In week six, the PV decreased slightly. It might be due to the fact that this test is limited by the chemical instability of the compounds, after their concentration reached a maximum, it decreased as a function of temperature. (Kanner & Rosenthal, 1992).

Further statistical analysis was conducted using ANOVA (7.9). This illustrated that there was no significant change in lipid oxidation over the six week period. This reveals that lipid oxidation is not a concern with respect to quality and safety.

Lipid oxidation was also measured at 4 °C and the results illustrated in figure 6.

Figure 6 . A graph of peroxide values versus time for the chocolates stored at 4 °C

Further analysis was done on the data illustrated in figure 6, by conducting a two sample t-test (7.9). The results from this statistical analysis illustrated that there was also no significant change in the lipid oxidation values over the shelf life testing.

Texture Analysis In food production, texture analysis is used for the measurement and control of process variations such as temperature, humidity and cooking time.

A compression test was undertaken to measure the texture in the shelf life testing to analyse the hardness of aerated cheese chocolate. The test was carried out in weeks zero, four and six using six replicates. In weeks four and six the samples stored at 4 °C and 25 °C were tested. The force needed to penetrate the chocolate product was obtained using the Micro Stable System Texture

15 Analyzer, Model HD Plus, fitted with 5kg load cell, heavy duty Platform, and a 6 mm cylindrical stainless probe. The probe was pre-set to 2 mm. The texture analyser software is loaded with a Macro (TPA32) which processed the results and displayed them in an excel spreadsheet. The texture analyser instrument also recorded a force time curve as shown in figure #.

Figure 7. Force time curve for Bubbly Cheese Chocolate

The results from the force time curve were analysed and displayed in a bar graph (figure 8).

Figure 8. Effect of temperature on the hardness of Bubbly Cheese Chocolate.

The chocolate samples stored at 4 °C showed an increase of in the hardness over the six weeks period. However there was a slight decrease in hardness from week 4 to week 6. The samples

16 stored at 25 °C showed a decrease in the hardness from week 0 to week 6. These samples also had a larger standard deviation compared to the samples stored at 4 °C. The graph in figure 2 shows a visual for the amount of compression force required to penetrate the bubbly cheese chocolate at 4 °C and 25 °C in weeks 0, 4 and 6.

To determine whether the change in the hardness of the bubbly cheese chocolate was statistically significant, one –way ANOVA test was carried for the samples stored at 4 °C and 25 °C over the six weeks shelf- life storage (7.9). It was found from this that the hardness in the samples were significantly different over time for both the 4 °C and the 25 °C samples.

It was noted that in both week 4 and 6 that a white coating appeared on the surface of the chocolate samples stored at 25 °C. Chocolate blooming is the main concern in the production of chocolate and this could be one of the reasons for the changes in the hardness of the aerated cheese chocolate. The whiteness of the chocolate stored at 25 °C would be due to fat or sugar blooming. Some of the factors that cause fat blooming are poor tempering, mixture of incompatible fats, disrupted cooling methods, temperature fluctuations and storage conditions (Beckett, 2000). In the production of the bubbly cheese chocolate, microwave was used for the melting process. To avoid fat blooming proper tempering methods should be used for the development of this product in future. If the chocolate is not properly tempered, incorrect crystalline structures are formed and this leads to blooming. When chocolate is exposed to high temperatures, the cocoa butter melts and separates from other ingredients. As a result the fat rises to the surface and causes an off white bloom. Sugar bloom is caused by excess moisture which causes the sugar in the chocolate to crystallise (Beckett, 2000). To prevent bloom from occurring before the shelf life expires, proper packaging and storage are important.

In conclusion, the microbial numbers indicate that the product will be safe during then 6 week period as the initial (week 0) and final (week 6) amounts were low enough for the product to be deemed as safe. Two of the six colour values that were measured (an L* a* and b* for two samples) varied significantly over the six week period- the L* value for the 25 °C and the a* value for the 4 °C sample. However, the group felt that the colour differences between the

17 samples during the six week period did not deem the product unstable or unsafe to consume, they just looked slightly different.

The results revealed that product is likely to be safe with regards to lipid oxidation as the peroxide values were very low.

The texture analysis results showed that there was a significant change in the hardness of the aerated cheese chocolate samples during the six weeks of shelf life storage.The main reason for the changes in texture was due to chocolate blooming .Proper tempering methods and good manufacturing practise should be put in place in order to increase the shelf life of the chocolate.

Further analysis is needed to fully confirm the shelf life of the chocolate. However in the shelf life tests ran over a six week period by chocolate innovation, the product was deemed as safe for the six weeks. It has been estimated that the product will hold a shelf life of approximately 6 months once some improvements in the processing techniques have been analysed (e.g. tempering improved). A longer shelf life test will need to be conducted to calculated exactly how long the product will be shelf stable for.

3.5 Food Regulatory Compliance Aerated cheese chocolate consists of Whittakers 50% dark chocolate (90%) and Waimata Blue Vein freeze dried cheese (10%). According to Food Standards Australia and New Zealand, 2016 (FSANZ), Food Standards code (FSC) 1.1.2 , chocolate is defined as a confectionary product characterised by, ‘the presence of cocoa bean derivative prepared from a minimum of 200g/kg of cocoa bean derivatives and does not contain more than 50g/kg of edible oils, other than cocoa butter or dairy fats. Cocoa means the powdered product prepared from cocoa beans from which a portion of the fat may have been removed, with or without the addition of salt or spice’. Whitakers 50% dark chocolate has already met the required standards as it is produced by a renowned chocolate company and available on the market. Waimata blue vein cheese powder is a dairy product, FSC 4.2.4 applies to this product. This code provides guidelines for primary production and processing standards for dairy products. Since Waimata blue vein cheese is

18 available on the market it meets the criteria set out in the standard. Refer to 7.10 for the nutritional information given on the packet of Whittaker's 50% dark chocolate and Waimata blue vein cheese.

Labelling Labels provide important information to consumers about the food they are buying. It helps the consumers to decide what to buy, meet dietary needs and in some cases prevent adverse or life threatening reactions to foods. Chapter 1 of the FSC includes general provisions for labelling foods for retail selling in New Zealand and Australia.

Product labelling requirements cover the following :The name and description of the new product , “Aerated Cheese Chocolate” was decided by the team and this will be printed on the package as it accurately describes the product. Aerated cheese chocolate has a shelf life of less than 2 years, therefore a date mark will be printed on the label. This chocolate product is developed for Giapos store, hence Giapos business name and physical address will be written on the packet .For warning and advisory statements on the package , blue vein cheese is a dairy product so it contains milk and also has Penicillium roqueforti. Whittakers dark chocolate contain traces of peanuts and tree nuts. FSC 1.2.3 covers food allergen labelling and applies to Aerated cheese chocolate. According to this code , the most common food allergens must be declared on food labels. Therefore milk, Penicillium Roquefort, traces of peanuts and tree nuts will be declared on the packet, using 3mm height for each word. The ingredient list and the nutritional panel information of aerated cheese chocolate is discussed in section 4.1 and will be stated on the packet as per section 4.1.The storage directions on the packet will be to store the chocolate in cool dry environment.

3.6 Consumer Acceptance The objective of the consumer acceptance study was to gain insight into consumer’s perception of innovative chocolate products, specifically the prototype we had developed. Ethics was written by the team and approved by Fiona, this also included the questionnaire. About 95 participants were recruited through a Facebook event inviting them to come along to the consumer acceptance test. There were also signs around university advertising the event.

19 Renuka and Sakinah were also able to recruit about 35 participants outside of the university to ensure the older portion of the target market was met, these people were given the same information and samples as those in the official trial held on campus. In total, the group was able to recruit 120 people for the consumer acceptance study. For the on campus trial, participants were given an information sheet regarding allergens and the purpose of the study. They were instructed to read the information before signing the consent form. Once this was completed, the two samples and questionnaire were handed to the participants. Participants tasted the Aerated Cheese Chocolate and indicated their overall liking on a unstructured 150 mm hedonic line scale. The intensity of the chocolate and cheese flavour was then indicated on a Just About Right (JAR) scale. Participants were then asked to focus solely on texture and compare the Aerated Cheese Chocolate with Cadbury’s bubbly chocolate and indicate which they preferred. Participants were then invited to leave a comment if they would like to. Finally, demographic information was collected including- gender, age, income and city of residence.

Analysis of Just About Right Scales (JAR) The intensity of two attributes, sweetness and the flavour of cheese, was rated on the Just Right Scale (JAR). The data was separated into three groups that were Above (too much), Below (too little) and Just About Right. For each of the three groups, the mean acceptance and the mean drop was calculated. The mean drop shows the difference between the hedonic average for the JAR levels minus the ‘too much’ and ‘not enough’ levels.

Table 5. JAR ratings for the intensity of cheese flavour Cheese Flavour Mean hedonic score Mean Drop Percentage of Consumers Not strong enough 101.96 -5.331 3.33 % Just About Right 107.29 N/A 86.60 % Too strong 68.92 -38.376 10 %

Table 6. JAR ratings for sweetness attribute Sweetness Mean hedonic score Mean drop Percentage of

20 Consumers Not sweet enough 60.20 -45.256 4 % Just About Right 105.46 N/A 85.80 % Too sweet 92.75 -12.706 10 %

Penalty Analysis The mean drop scores were plotted against the percentage of consumers as shown in Figure 9 below. This was important to suggest directions in order to modify the product.

Figure 9. Mean Drop score versus the percentage of total consumers in each group.

As shown in figure 9 above, there was a large group who thought it was ‘too sweet’ but it had a low mean drop so no action need to be taken. Regarding the intensity of sweetness, there was a small but a strongly dissatisfied group in the upper left corner.

21 A large group of consumers thought the cheese flavour was ‘too strong’ and had a large mean drop. This suggests an area for improvement by reducing the intensity of the cheese flavour in the chocolate.

ANOVA Anova analysis was performed on the overall hedonic ratings of males and females to determine if they rated the product significantly different. Anova was also performed on the overall hedonic ratings between people that rated blue cheese flavour as negative (too little) and positive (too much cheese flavour) to see if there was a significant difference in how they rated the product. Anova was also run to see if there was a significant difference in how those who did the consumer test on campus compared to those who did it off campus rated the product.

Table 7. ANOVA for Overall Liking for Males and Females

The ANOVA test results in table 7 conclude a p-value of 0.59 (2sf), which is greater than 0.05, therefore the difference in overall hedonic ratings between males and females is not significant at 5% level. Specifically that males (104.69) did not like the product significantly different to females (101.57).

22 Table 8. ANOVA for Overall Liking for People that Rated Blue Cheese Flavour as Negative (too little) and Positive (too much cheese flavour).

The ANOVA results in table 8 show that there was a significant difference (p-value 0.041, 2sf) between how people who thought there was too much and people who thought there was too little blue vein liked the product overall. Specifically, people who indicated that there was too much Blue Vein cheese gave a lower overall rating (93.97) and the people who indicated that there was too little Blue Vein cheese gave a higher overall rating (107.13). 62 of the 120 participants thought that there was too little cheese, 31 thought there was too much and 27 thought it was just right.

Based on the results in table 8, it is appropriate to infer that people who indicated that there was too much blue vein cheese in the product do not particularly like the taste of cheese and therefore found it very strong. These people would be unlikely to rate the product highly (on the hedonic scale) as they do not like the cheesey flavour. However, the average hedonic score was still larger than 75mm (halfway) and therefore it was interpreted as a positive response. People who indicated that there was too little blue vein cheese in the product are likely to enjoy blue vein cheese and therefore wish that it be stronger. These people enjoy the taste of cheese flavour as they like cheese itself so they are more likely to indicate that they liked the product a lot. In future, it may be of use to include a range of chocolates with differing cheese percentages (e.g., 2.5%, 5%, 10%, 15% and 20%) and have consumers indicate which percentage they prefer. The rationale for this is that there were 62 people who thought there was too little cheese and 31 who

23 thought there was too much cheese. Therefore, it would be useful to have them indicate how much more or less cheese they would prefer. Ultimately, the group felt that the cheese flavour should be increased as only those who enjoy blue vein cheese will purchase the product. These people will expect a strong cheese flavour and enjoy it.

Table 9. ANOVA for Overall Liking For Testing Done at The University of Otago and the Testing Done Outside The University

The ANOVA results in table 9 show that the overall liking for people who were tested in the University was significantly different (p-value 0.0044, 2sf) to people who were tested out of University. Specifically, that people who were tested outside of the university rated the product lower (87.58, 2dp) and those who were tested inside of the university rated the product higher (106.37, 2dp). The significant difference between the results testing inside university and the result collected outside the university could be due to multiple reasons. Firstly, the samples made for the outside campus testing were made at a different time to the samples that were tested this meant that they looked different and it is possible that they had a slightly different composition. Secondly, the on campus testing was done in sensory booths which may have altered the perception of the product. Ideally, if the test were to be run again it would be better to run it all in one location so that variation between hedonic ratings could be minimised.

24 Paired Preference A 2-tailed test was used to compare the texture preference data. For the preference in texture to be significantly different, a minimum requirement of 72 from 120 consumers was needed to indicate a preference towards one sample (see appendix B for the table used). This would indicate that a significant difference in preference for texture exists between ‘Cadbury Bubbly’ and ‘Bubbly Cheese Chocolate’ at 5% level. 82 of the 120 participants preferred the texture of Aerated Cheese Chocolate. 38 participants preferred the texture of the Cadbury bubbly chocolate. Based on the results from the 2-tailed test, there is a preference for the texture of ‘Bubbly Cheese Chocolate’. In the comments section of the questionnaire, participants indicated that they preferred the texture of the Aerated Cheese Chocolate as it crumbled in the mouth, was smooth and melted easily.

Based on the results from the consumer trial, the group felt as though it would be a good idea to introduce a range of chocolates varying in blue vein cheese content from very weak (2.5%) to very strong (20%). Another trial would need to be done to ensure the product meets consumers’ demands. It is also vital that in the future, the samples are made to the same quality standard as when they are not (the outside of university prototypes), consumers indicate their negative opinion thus lowering the average overall liking.

3.7 Costing and Marketing Table 10. Ingredient Sources and Prices Item Name Brand Retail Price Weight Supplier 50% Dark Block Whittaker’s $4.99 250g City Centre New World. Chocolate 133 Great King St., North Dunedin. Ph: 03-477-4677 Blue Vein Cheese Waimata $5.49 100g Countdown 309 Cumberland St., Dunedin. Ph: 03-477-7283

25 As seen in table 10, the raw materials were purchased at supermarket price. The Whittaker’s chocolate cost $4.99 per 250 g and the Waimata Blue Vein Cheese cost $5.49 per 100 g.

The cost was calculated per gram, because the composition is 90% chocolate and 10% cheese. A chocolate weighs 8 grams and 90% of 8 grams is 7.2 g (chocolate) and 10% is 0.8 g (cheese). Costs of ingredients in section 4.0, table 11. 7.2 g was multiplied by $0.02 (which is the retail price of the chocolate) and added to 0.8 g multiplied by $0.087 (retail price of cheese), giving a total cost of $0.22 per 8 g chocolate. As the chocolates are sold in a pack of 3, the total cost of all three will be $0.66. To get the retail price, $0.66 is multiplied by 2 and an extra $0.40 is added in order to make profit, totalling $1.72. Labour and packaging is estimated to be $0.80 on top of this. Therefore, the cost of a packet of 3 chocolates is $2.52. Refer to section 7.8, appendix H, for all product costings.

Each piece of Aerated Cheese Chocolate weighs 8 g which adds to c per piece. Furthermore, the product will be sold in packs of three chocolates with the addition of estimated labour and packaging materials cost, the product is to be sold for $2.52 per pack. This retail price would be much lower if the ingredients were to be purchased at wholesale price.

In comparison to other chocolate products, there is no similar chocolate available on the market that contains cheese and this eliminates competition in terms of price. However, Lindt sells a small pack of four luxury chocolates for approximately $5.30, so this makes aerated chocolate a much more affordable option.

Marketing The marketing strategies involve launching the product at the Food and Wine event in 2017. This ensures the presence of a large audience will be exposed to the product, which is critical to the success of a new product.

To elevate the audience and customer base, social media will be used for promoting the product. The sponsor is active on social media such as Facebook and Snapchat and has many followers therefore it is vital to use these platforms for promotion to gain more attention for the product.

26 The advantages of this strategy include being inexpensive and its potential to reach a wide group of audience.

The place at which the product is sold plays a fundamental role in marketing. For this reason, it has been decided to sell the products within Giapo’s store which is located on Queen street. This would be an effective positioning plan because around 200,000 consumers visit Giapo’s store per year and 80% of them are said to be regular customers (Richardson, 2013). Thereby, it would be the right place to sell this product to the customers as it would ensure a wide customer base.

Due to the fact that there is no similar product on the market and this difference establishes a unique position in the market. There is the advantage of having no competition by being first in the market.

4.0 Specifications

4.1 Final formulations/processing instructions/quality criteria/process yields and costings

Table 11 outlines the costs and amount of ingredients that are used in a typical batch of Aerated Cheese Chocolate.

Table 11. Formulation for Shelf Life Test Samples and the Costs of the Ingredients Used. Ingredient Amount (per batch) Cost of Ingredient (per gram) Freeze Dried Waimata Blue 92 g $0.087/g Vein Cheese Whittakers Dark Chocolate 828 g $0.02 / g

Yields for the cheese were calculated by first weighing the container the cheese was put in. Secondly, the amount of cheese in the container was then weighed before it went into the cheese drier (and the weight of the container was removed from this), giving the initial weight of cheese.

27 Finally, the amount left in the container was weighed once it was freeze dried and the container weight was removed from this, giving the yield. As shown in table 12 the yield for the cheese was a 62.3%, this yield is so low because a large percentage of the cheese is water. When it is freeze dried the available moisture is removed therefore, lowering the weight. It is imperative that this water is removed as the water activity of the product cannot exceed 0.6 aw. Yields for the mixture were obtained by first weighing the bowl the chocolate mixture would be made in. The chocolate and cheese powder were then weighed in the bowl (and the bowl weight was removed), giving the initial weight. The mixture was then weighed again (in the bowl) after all the piping had been done, the weight of the bowl was removed and the final process yield was calculated. As shown in table 12, the process yield was 73.3%, this was thought to be due to the chocolate sticking to surfaces such as the bowl, whisk and piping bag.

Table 12. Processing Yield for the Product Illustrating the Yield after Freeze Drying the Blue Vein Cheese and the Overall Product Process Yield Product Amount before Amount After Process Yield processing (g) Process (g) Waimata Blue Vein 100 62.3 62.3% Cheese Bubbly Cheese 920 675 73.3% Chocolate

The process to make the chocolates is a timely one, requiring preparation and setting time. A complete process can be seen in figure 10. The preparation process consists creating the freeze dried cheese powder. Approximately 4 days before it is needed, the blue vein cheese is placed in the freezer. The next day it is then grated and placed into containers covered in perforated tin foil. The containers are then placed in the freeze drier for about 3 days. Once the cheese is freeze dried, it is then ground into a fine powder using a mortar and pestle. It then weighed out and is then ready to be added to the chocolate. The chocolate is weighed out into a microwave-safe bowl and broken into squares. It is then placed in the microwave set at 80% power and heated in 1 minute increments and is stirred after

28 each minute. Once the chocolate is melted, the weighed cheese powder is then added to the chocolate. The mixture is then whipped using a whisk for about 5 minutes. The mixture is then transferred to a piping bag and piped into the moulds, ensuring each one is about 8 grams. Once all the mixture is piped, the moulds are placed into the vacuum, which is set at a light vacuum of 2.5 for about 2 hours, until they are set. Once the chocolates are set, the moulds are removed from the vacuum and placed in sealed glad bags. They are then removed from the moulds the next day and packaged in a sealed bag.

29

Figure 10 . Process Flow Diagram.

4.2 Nutritional information (NIP) and if relevant nutritional claims/ health claims Nutritional information Panel The nutritional information panel (NIP) was calculated based on the concentrated cheese powder added to the chocolate, with the final product having 90% Whitakers dark chocolate and 10% freeze dried blue vein cheese powder. The nutritional information panel in table 13 shows the

30 average amount per serve and per 100g of energy (in kilojoules), protein, fat, saturated fat, carbohydrate, sugars (in grams) and sodium (in milligrams) in Aerated Cheese Chocolate.As mentioned in section 3.5 , cows milk, Penicillium Roquefort, traces of peanuts and tree nuts are the food allergens present in the chocolate product and these will be declared on packet label.

Table 13. Nutritional information panel for Aerated Cheese Chocolate Nutrition Information Servings per package: 1.00 Serving size: 24 g

Average Quantity per Average Quantity per 100 g Serving Energy 555.6 kJ 2315 kJ Protein 2.1 g 8.2 g Fat, total 8.1 g 33.4 g - saturated 5.1 g 21.4 g Carbohydrate 13.2 g 55.4 g - sugars 11.28 g 47.0 g Sodium 41.1 mg 171.7 mg Ingredients: Whittaker’s 50% dark chocolate (90%) [dark chocolate (cocoa solids 50%-cocoa mass & cocoa butter) sugar, emulsifier (soy lecithin, vanilla flavour)], Waimata Blue Vein cheese (10%) [salt, Vegetable coagulant, culture, Bacterium linens] Contains : Cows milk, Pencillium roqueforti May contain traces of peanuts and tree nuts

When comparing the nutrient composition, to the average amount per 100g in the Whittakers 50% dark chocolate, every nutritional component increased with the addition of the blue vein cheese powder, apart from the sugar content which decreased slightly. The biggest difference was seen in the amount of sodium as it increased from 15 mg/100g in the original chocolate to 171.7 mg/100g in the final product. According to New Zealand Nutrition Foundation, the recommended daily intake of sodium for adults is 920- 2300mg/day (NZ Nutrition Foundation,

31 2013). Table 14 shows the recommended daily intake of sodium for men and women in New Zealand.

Table 14. Recommended daily Intake of Sodium

Age (years) Sodium (mg/day) Adults 19-70+ 920-2300

Each packet contains one serve of 3 chocolates (3x8 =24g). A person might eat two to three pieces at a time, therefore a serving size of 24g was decided. This implies that a person will be consuming 555.6 kJ of energy, 2.1g of protein, and 8.1g of total fat, 13.2g carbohydrate and 41.1mg of sodium per serve.

Health claims Food standard code 1.2.7 sets out the rules for making nutrition content and health related claims (Food Standards Australia New Zealand, 2016). Aerated Cheese chocolate is designed as a confectionary product that can be taken as a treat and the team decided not to make any nutrient or health claims for it.

4.3 packaging design and specifications Primary Packaging The primary packaging is comprised of printed aluminium foil (40 µm thick). This high barrier material enables the product to be shelf stable and retain its quality, particularly as the product is prone to lipid oxidation as it has a reasonably high fat content (33.4 g per 100 g). The foil packaging material is vital to block light and oxygen from reacting with the product and hence each chocolate will be wrapped in this material. Printstock Products Ltd is the packaging manufacturer for Whittaker’s products and is an excellent source to supply the aluminium foil for this product (Printstocknz, 2016).

32 The dimensions of the chocolate is shown below in Figure 11.

Figure 11. Chocolate measurements in cm

The foil wrapping will be designed to fit the product’s dimensions. The following figure 12 illustrates how the chocolate will be wrapped.

Figure 12. Primary packaging of a chocolate piece wrapped in foil.

The aluminium foil wrapper will be printed in two different shades of gold as illustrated above.

33 Secondary Packaging Once the chocolates are covered in the primary packaging, the chocolates will be placed in cardboard box in sets of three. The secondary packaging material will be comprised of a gold coloured printed Kraftboard box and wrapped in colourless cellophane film. The cardboard box will protect the product from physical damage and the cellophane is resistant against air and dust. Thinkpack would be the ideal company to supply the cardboard (Thinkpack, 2016) and Printstock Products Ltd would supply the cellophane film.

Figure shown below illustrates the template for the cardboard box that will carry the three chocolates.

Figure 13 . Secondary packaging open cardboard

The cardboard box template shown in figure 13 will be folded and the edges will be glued together to form a rectangular box. The box will be packed with three chocolates and finally the box will be covered in cellophane and sealed.

34 The dimensions of the cardboard box were designed to allow for variation in chocolate size and space so that the chocolates are not squeezed together. 1 cm was added on to the length and width, and 1.3 cm was added to the depth of the chocolate’s dimension for the secondary packaging material. Hence, the total length and width of the secondary packaging material required for each pack of 3 chocolates is 8.5 cm and 3.5 cm respectively.

The following figure illustrates the folded packaging material that will hold the three chocolates.

Figure 14 . Secondary packaging

The dimension of the package is 8.5 cm × 3.5 cm × 3.5 cm (length × width × depth). In order to pack the chocolates into boxes, no complex machinery such as the top-loader is necessary. This is because the chocolates will be produced on a small production scale. Furthermore, the products will be made on site at Giapo’s kitchen and typically a batch of 30 samples (10 packs) will be made to ensure it is a well controlled process.

The package is designed with an open top so that the glossy golden foil wrapped chocolates are visible through the cellophane. This enhances the attractiveness of the packaging and in turn make the product more appealing to consumers.

35 In addition, the gold Kraftboard box will have black lettering as shown in figure 14. The specific colours were chosen because that is the theme of Giapo’s logo. This product is reasonably expensive and these colours reflect the luxury product within. All regulatory requirements will be included in this packaging as outlined in section 3.5. Labelmakers Group Pty Ltd could provide the service for labelling as the company is highly specialised in product label printing (Labelmakers, 2016).

With regards to recyclability, the aluminium foil and cardboard are both recyclable. However, cellophane is a plant based plastic and hence it is not recyclable but is biodegradable and compostable (Bloch, 2012).

5.0 Project conclusion and recommendations The original brief of incorporating bacteria into chocolate and enabling them to survive was found to be too unrealistic for the group to achieve. We experimented with many things including growing bacterial cultures in milk, creating our own chocolate, creating a cheese using chocolate milk, and adding bacteria to chocolate. We researched which bacteria would grow in chocolate as it had such a low water content but could not find any options. We tried to increase the water activity by adding water and an emulsifier to the chocolate however this was ultimately unsuccessful. Whilst trying to fulfil the original brief we found a creative alternative. Our final decision for the prototype was to use cheese flavours to imitate the flavours bacteria produce.

Aerated Cheese Chocolate is a new product in the New Zealand market and based on consumer acceptance study results, it seemed to be well liked. The product is to be packaged in a set of 3, priced at about $2.52. Aerated cheese chocolate will go well as an after dinner delicacy or as a classy addition to a cheese board. It has a an estimated shelf life of 6 months, which means that those who find it rich do not have to concern themselves with eating it all in one sitting. The product will be launched in conjunction with another event such as Food and Wine, 2017 to ensure a large audience is present. Constant advertising and information will be available on Giapo’s facebook page and website. There is still work to be done regarding the final optimisation of the product including determining the ultimate blue vein percentage and the

36 guaranteed shelf life. However, we feel as though we have created an innovative product that has a huge potential in the New Zealand market.

37 6.0 References

Amano Artisan Chocolate (2016). Sugar and Fat Bloom. Retrieved from: http://www.amanochocolate.com/sugar-and-fat-bloom-part-1 (12/10/2016).

ASHOP., (2013). New Zealand’s Premium. Retrieved from: http://www.ashop.co.nz/Dark- Block-Chocolate (28/07/2016).

Associated Newspapers Ltd. (2015). How AGE affects our taste in food: We only start liking olives, anchovies and blue cheese in our twenties, survey reveals . Retrieved from http://www.dailymail.co.uk/health/article-2950608/How-AGE-affects-taste-food-start-liking- olives-anchovies-blue-cheese-twenties-survey-reveals.html (17/07/2016)

Bloch, M. (2012) Green Living Tips. Retrieved from: https://www.greenlivingtips.com/articles/cellophane-a-green-plastic.html (10/10/16).

Canstar Blue (2016). Chocolate Ratings . Retrieved from: http://www.canstarblue.co.nz/food- drink/chocolate (12/10/2016) .

Confectionary News, Oliver Nieburg (2014). Cocoa flavanols may reverse memory decline, but not in chocolate, say Mars-backed study. Retrieved from: http://www.confectionerynews.com/R-D/Cocoa-flavanols-in-chocolate-insufficient-to-reverse- memory-decline (/2016)

Food Standard Australia New Zealand. (2016). Nutrition Content Claims and Health Claims. Retrieved on 10th October 2016 from http://www.foodstandards.govt.nz/consumer/labelling/nutrition/Pages/default.aspx

Francis, S. T., Head, K., Morris, P. G., & Macdonald, I. A. (2006). The effect of flavanol-rich cocoa on the fMRI response to a cognitive task in healthy young people. Journal of cardiovascular pharmacology , 47 , S215-S220.

38

Giapo. (2014). Haute Ice Cream. Retrieved from: http://giapo.com/. (Access date: 28/03/2016)

Hussaini, S., Little, H., , Purdy, V. & Reddy R., (2016). Technical Literature Review.

Idealog (2014). It's official: Kiwis and Aussies are the biggest per capita chocolate bingers in the world . Retrieved from: http://idealog.co.nz/venture/2014/11/kiwis-and-aussies-biggest-capita- chocolate-bingers-universe-while-choc-makers-face-prospect-bleak-cocoa-supply (/2016)

Kaleem, A., Aziz, S., Iqtedar, M., Abdullah, R., Aftab, F. R., Shakoori, F. R., & Naz, S. (2015).Investigating changes and effect of peroxide values in cooking oils subject to light and heat. Fuuast Journal of Biology , 5(2).

Kanner, J., & Rosenthal, I. (1992). An assessment of lipid oxidation in foods (Technical Report). Pure and applied chemistry , 64 (12), 1959-1964.

Kilcast, D., & Subramaniam, P. (2011)Kilcast, D., & Subramaniam, P. (Eds.). (2011). Food and beverage stability and shelf life . Elsevier.

Konica Minolta Sensing. 2016. Identifying Colour Differences Using L*a*b or L*C*H coordinates . Retrieved on 25th of September 2016 from: http://sensing.konicaminolta.us/2014/04/identifying-color-differences-using-l-a-b-or-l-c-h- coordinates/

Labelmakers. (2016). Australasia’s Experts in Product Label Printing and Packaging Solutions. Retrieved from: https://www.labelmakers.com.au/ (13/10/16).

Lawlor, J. B., Delahunty, C. M., Sheehan, J., & Wilkinson, M. G. (2003). Relationships between sensory attributes and the volatile compounds, non-volatile and gross. Technology of Cheesemaking.

39 Mastroiacovo, D., Kwik-Uribe, C., Grassi, D., Necozione, S., Raffaele, A., Pistacchio, L., ... & Ferri, C. (2015). Cocoa flavanol consumption improves cognitive function, blood pressure control, and metabolic profile in elderly subjects: the Cocoa, Cognition, and Aging (CoCoA) Study—a randomized controlled trial. The American journal of clinical nutrition , 101 (3), 538- 548.

NZ Nutrition Foundation. (2013). Minerals, Sodium. Retrieved on 10th October 2016 from http://www.nutritionfoundation.org.nz/nutrition-facts/minerals/sodium

Printstocknz. (2016). Printstock Products Ltd Services. Retrieved from: https://www.printstocknz.com/services/ (13/10/16).

Richardson, T. (2013). Innovation in Action. Pg 3 Retrieved from: http://giapo.com/wordpress/wp-content/uploads/2013/04/TRichardson152334CaseStudy.pdf

Thinkpack. (2016). Cardboard Engineering. Retrieved fom: https://thinkpack.co.nz/pages/about (13/10/16).

40 7.0 Appendices

7.1 Appendix A – Project Brief

Project proposal Aim: a) To study the physico-chemical properties including pH of different types of chocolates, viz., dark chocolate, milk chocolate and white chocolate, and milk powder (full-fat and low-fat). b) To inoculate the bacteria/yeast in order to make the chocolate more acidic in nature 1) Inoculate all the chocolate types(milk based) and milk powder 2) Create a mix of the milk chocolate/ milk powder-already inoculated with bacteria and the chocolate powder. c) Determining the characteristics of the bacteria which are temperature resistant over the range of 30°C to 48°C and then eventually grow them in chocolate, making it temperature resistant. Materials required: a) Ingredients required for studying the physico -chemical properties: 1) Milk chocolate 2) Dark chocolate 3) White chcolate 4) Full fat milk powder 5) Low fat milk powder b) Ingredients required for inoculating dark chocolate/ milk chocolate or white chocolate with specific yeast and bacteria strains to make it more acidic: 1) Dark/ milk and white chocolate 2) Full fat and low fat milk powder 3) Lactobacillus bulgaricus, 4) Xanthomonas Campestris

41

7.2 Appendix B – Project Plan

Table 15. Project Task List

Objective Task/Activities List Start Date Status

Concept introduction - Create a team name and write to Complete sponsor

- Create project goals and discuss

what will make these successful - Research on sponsoring company and potential target markets - Plan Consumer research – initial draft of ethics proposals

Complete all First Project Report 15 th March Complete introduction processes and have a written up report.

Ethics proposals for consumer 15 th April Submitted 6th May testing (Reference Number: 13/278) Ethics Accepted.

Prototype Experimenting chocolate from Complete Development scratch

Experimenting with cheese Complete powder

Experimenting aerated chocolate Complete

42 Freeze Drying cheese and putting 12th May Complete this into chocolate

Complete Concept Second Project Report 14 th April Complete Development

Presentation Team presentation to be 14 th April Complete presented in lab time

Sourcing Bacteria Cultures 28th April Bacteria cultures sourced and received

Technical Literature Formulation and Processing Trials Continuous Complete Review From above experiments

Prepare for shelf life testing Complete

Third Project Report – 20th May Complete technical literature review

Inter-Semester Break (Lab is open 8.30am-5pm during the break)

Shelf Life Testing 4a Project Report - Detailed 20th May Complete shelf life test plan

Scale up for the shelf life test 11 th July Complete

HACCP 5th Project Report – HACCP 15 th July Complete

Development on product and shelf 1st August Complete life

Prototype Presentation on prototype 11 th July Complete development development summary

43 6th Project Report – Prototype 11 th July Complete development

Finalising Shelf life Finalise Shelf life testing and 1st August Complete prepare for consumer testing

7a Consumer Acceptance Test 29 th August Complete and Ethics Proposal Ethics Approved

4b Project – shelf life test results 1st August Complete

Run Consumer Acceptance Test 20th September Complete

7b Project Report – Consumer 15 th September Complete Acceptance Test results

Final Presentation 19th September Complete

Final Report 26th September 14th October

7.3 Appendix C – Idea Generation List

• Homemade chocolate • Probiotic Chocolate • Chocolate Cheese • Lactic acid bacteria in milk • Water + emulsifier in chocolate • Parmesan cheese flavoured chocolate • Blue vein cheese flavoured chocolate • Freeze dried blue vein cheese chocolate- 2.5, 5, 10 & 15% • Aerated chocolate

44 7.4 Appendix D – Consumer market research summary

After changing from initially targeting consumers aged 40 and above, then consumers aged 22 and above, chocolate innovation has defined the final target market as those aged 18 and over.

Research done in the UK shows that (Associated Newspapers Ltd., 2015) people begin to like foods such as blue vein cheese, olives and anchovies when they reach an age of 22. This is due to a decline in taste buds which means that the taste is not perceived as intensely (Associated Newspapers Ltd., 2015). For this reason, the group felt as though a majority of the target market would enjoy the blue vein cheese flavour. The consumer acceptance study showed that those aged in the youngest age bracket (18-20) enjoyed the product as well so the target market was changed from 22 to 18 and over.

Chocolate is a very popular snack in New Zealand with each person consuming about 4.8kg annually in 2013 (Idealog, 2014). Therefore, the product should slot easily into the forever hungry chocolate market. According to analysis done by the US Department of Agriculture, a 100g bar of dark chocolate contains about 53.49mg of cocoa flavanols (41.50mg of epictechin and 11.99mg catechin) ( Confectionary News, Oliver Nieburg., 2014) . There are many health benefits associated with consumption of cocoa flavanols such as increased blood flow, cognitive function and cardiovascular health. Our product uses dark chocolate, with 50% cocoa solids, so a significant amount of cocoa flavanols are present. Research done by ( Mastroiacovo et al., 2015 ) shows that with regular cocoa flavonoid consumption, some effects of aging such as cognitive dysfunction are reduced. For this reason, our product should appeal to elderly as well as younger consumers as it provides a health benefit, therefore we did not set an upper limit to the target market. A pilot study for Francis, Head, Morris & Macdonald’s (2006) experiment showed that a single dose (450mg) of cocoa flavanols can increase the cerebral blood flow to grey matter in healthy, young individuals. This study suggests that there is potential for cocoa flavanols to be used in the treatment of vascular impairment, dementia and strokes and maintaining good vascular health ( Francis at al., 2006) .

45 7.5 Appendix E - Bill of Materials Table 16. Bill of Materials for the Products used in Aerated Cheese Chocolate Item Name Brand Retail Price Weight Supplier 50% Dark Block Whittaker’s $4.99 250g City Centre New World. Chocolate 133 Great King St., North Dunedin. Ph: 03-477-4677 Blue Vein Cheese Waimata $5.49 100g Countdown 309 Cumberland St., Dunedin. Ph: 03-477-7283

46 7.6 Appendix F - HACCP Summary Table Table 17. HACCP Summary Table

Process Hazard CCP Critical Limit Monitoring Procedure Corrective action to Verification HACCP Step # # Target and be taken by specified Records Tolerance Procedure who, what, Frequency responsible person Levels when & how

1. Intake raw Microbial and physical 1 Zero tolerance Check package integrity On arrival of Return the inward Supplier audits, Record of materials contamination, chemically level on arrival. every batch goods back to the internal audits inward goods. Unknown allergens. Obtain certificate of suppliers. quality assurance from supplier.

9. Grind the High water activity greater 2 Aw <0.6 Check the water activity Routinely Retain and discard the Internal audits Record of dried cheese than the limit can lead to of a sample from each product and stop water activity. into powder microbial batch production, investigate Record of the source of microbial inaccuracy. checks.

10 - High water activity greater 3 Aw <0.6 Check the water activity Routinely Retain and discard the Internal audits, Record of Blending than the limit can lead to of a sample from each product and stop calibration water activity. cheese microbial hazard (chocolate batch production, investigate Record of powder into bloom). the source of microbial melted inaccuracy. checks. chocolate

16- Metal Metal fragments from 4 No presence Check every batch using Routinely Retain and discard the Internal audits, Record of detection machinery, pieces of metal a metal detector product and stop maintenance of maintenance aluminium foil. fragments production, investigate machinery, of machinery the source of calibration usage. contamination

46 7.7 Appendix G - Consumer Acceptance Test Ballot Form and Statistical Summary Tables

47

48 49 50 51 52

53 7.8 Appendix H - Product Costings Table 18. Product Costings Item Name Price Per Chocolate Price per Packet (3 chocolates, 24 g)

Raw Materials $0.22 $0.66

Labour $0.20 $0.60

Packaging $0.07 $0.20

Total Cost $0.49 $1.46

54 7.9 Appendix I - Shelf Life Stattistical Analysis

Colour ANOVA Table 19. ANOVA for L* Values for 4°C Samples

Table 20 . ANOVA for a* Values for 4°C Samples

Table 21 . ANOVA for b* values for 4°C Samples

55

Table 22. ANOVA for L* values for 25°C Samples

Table 23. ANOVA for a* values for 25°C Samples

Table 24. ANOVA for b* values for 25°C Samples

56

ANOVA FOR LIPID OXIDATION Table 25. One-way ANOVA for lipid oxidation results at 25°C Samples

Table 26 . Independent two sample t-test for the sample at 25°C and 4°C.

57

TEXTURE ANOVA Table 27. ANOVA Test Results for Samples Stored at 4°C

Source SS df MS F P-value F crit of Variatio n Betwee 6633249 2 331660 37.2288 0.00041 5.14325 n 6 5 3 Groups Within 5345242 6 890873. Groups 7 Within 7167766 8 Groups 1

58

Table 28. ANOVA Test Results for Samples Stored at 25°C

Source SS df MS F P-value F crit of Variati on Betwee 329935 2 164967 8.88862 0.01606 5.14325 n 0 5 6 8 3 Groups Within 111356 6 185593. Groups 3 9 Within 441291 8 Groups 3

59

7.10 Appendix J – Raw Materials Whittaker’s 50% Cocoa Dark Block Chocolate (ASHOP, 2013).

Figure# Waimata Blue Vein Cheese Packaging and Nutrition Information Panel

60

7.11 Appendix K – Total Expenditure Table 29 . Chocolate Innovation’s Total Expenditure

61