Paper No.: 09

Paper Title: BAKERY AND CONFECTIONERY TECHNOLOGY

Module – 28: Technology of Caramel, Toffee and Fudge

Paper Coordinator: Dr. P. Narender Raju, Scientist, ICAR-NDRI, Karnal

Content Writer: Mr. Borad Sanket, Scientist, ICAR-NDRI, Karnal 23. Caramel, Toffee and Fudge 1. CARAMEL

 History

• Candies of fruit and nuts dipped in honey

were prepared

• 1st invented in 19th century in the USA

 Originally copper pots were used for the production of caramel which were placed directly on the gas flames

 Master confectioner used to observe the temperature carefully and than it was cooled on marble slap followed by scoring it into pieces Background

 Caramels- “soft glasses” viscous in nature, contain a dispersion of milk protein and an emulsion of fat

 Delicious, chewy treats, found in a range of textures, colours, flavours and products

 Sweet and a bit chewy- the most desirable

 Short- a caramel that is too soft (perhaps too moist)

 Long- a caramel that is quite chewy

 Caramels are softer because of lower cooking temperature (118°C) than hard candies and contain more moisture Cont…  Caramel- easy to mould and also in variety of candies to add flavour, binding and texture.  Heat + milk solids + sugar ingredients = a typical caramel flavour  The chemical reaction referred as the Maillard reaction – responsible for development of attributes of caramel Raw Materials  Different raw materials - depending on the manufacturing and type of caramel production  Most frequently made caramel: The vanilla caramel - include milk, sometimes sweetened condensed milk, corn syrup, sugar, oil, whey, calcium carbonate, salt, flavour, butter, another type of fat such as vegetable oil, molasses, and corn starch.  Milk – essential ingredient to distinguish the caramel from a hard candy  Milk solids - change chemically to produce the caramel Cont…

 Corn syrup - additional sweetness, also protects the mixture from becoming grainy

 Corn syrup also imparts body to the slurry

 Butter - often the only fat added by gourmet caramel-makers - it provides superior taste

 But very expensive for mass-production

 Other fats - added along with a fairly small amount of butter  The Manufacturing Process

 Several methods - used in industry

 A batch method: also employed - as below

Weighing of Ingredients accurately

Loading of liquid and dry ingredients in the machine

Mixing of ingredients by propellers in the weigh tank

Heating of slurry to dissolve ingredients Cont… Final evaporation in the SSHE

Syrup is forced through a small space jacketed with steam, thus forcing evaporation within the mixture

Caramelization by heating at 1150C

Cooling of the product

Shaping of the caramel

Source: Weighing, packaging and storage E. B. Jackson, Sugar confectionery manufacture  Quality Control

 To much sugar - caramel becomes grainy  Too much moisture - too gooey in warm weather  Too little moisture/cooked to high heat - “long” or chewy caramel  Insufficient mixing during cooking – either of any of:- Grittiness due to uneven dispersion of proteins Oily taste due to incomplete emulsification of fat  Quality Control - necessary for avoiding problems  Quality of all consumable ingredient - must be checked  Product quality depended totally on the skill of the confectioner 2. Toffee

• Word Toffee derived from ‘taffy’, a dialect word for ‘sticky’

• Toffee: high sugar boiled confectionary

• Low moisture content, chewable and harder texture

• Ranging from viscous liquid to hard sugar glass

• Nearest the oil in water emulsion, continuous phase of sugar and glucose syrup

• Caramel and Toffee – used interchangeably in many countries Ingredients

• Sugar

• Glucose syrup

• Milk protein

• Fat

• Salt

• Water

• Other additives e.g. colour, flavour etc. Structure Of Toffee

• Emulsion of fat in complex aqueous system

• Mixture of sugars, water and protein - resistant to crystallization

• Toffees - number of textural characteristics:

• Hardness - function of moisture content.

• Chewiness and toughness - related to molecular weight of the carbohydrates

• Body - function of quantity and state of the milk protein -affected by quantity ,degree of emulsification and hardness of fat Formulations

• Depends on the requirements of the toffee

• May be for wrapping as a sweet, for depositing into chocolate shells or layering on to other confectionary products

• Balanced recipe contains 3 parts of sugar, 5 parts of glucose syrup, 3 parts of sweetened condensed milk and 1 part of fat

• For wrapped toffees, the ration of sugar to non-crystallizing sugars should be 1.1:1

• Milk protein used up to 2 % acceptable  The Manufacturing Process

Weighing of Ingredients accurately

Dissolving the sugars in the water and glucose syrup

Mixing of fat and SMP to the aqueous phase

Emulsification of the mixture

Cooking of emulsion to achieve final moisture content Cont… Shaping of the finished toffee

Cooling of the toffee

Packaging and storage

Source: E. B. Jackson, Sugar confectionery manufacture 3. FUDGE  INTRODUCTION

• Fudge - grained product - a ‘fondant’ containing milk protein and fat, often butter fat

• Characteristic flavour of caramel or toffee

• A cross between caramel and cream

• Wide range of texture from the hard ‘snappy’ to the soft tender texture

• Often an egg whip added for light ‘fluffy’ texture Ingredients

 Basic ingredients are: • Sugar • Glucose syrup • Milk protein • Fat • Salt • Water Composition

Components Proportion

Reducing sugar solids 17-25%

Sugar 45-55%

Fat and Milk solids 20%

Moisture 7-10% Processing

 Basic unit operations are:

• Pre-mixing

• Emulsification

• Cooking/Caramelization

• Cooling

• Graining

• Forming  The Manufacturing Process

Mixing of all ingredients (Fat, Milk, Glucose syrup, Sugar, Salt and Water)

Emulsification of ingredients using high speed stirrers or ultrasonic homogenizers (70-80°C for 10-20 min.)

Cooking/Caramelization with constant stirring (116°C for 20 min.)

Cooling of the mixture to below 105°C Cont…

Addition of fondant for Seeding/Graining

Filling into trays

Cutting and Wrapping

Packing in heat-sealed polythene bags

Source: Storage at room temperature E. B. Jackson, Sugar confectionery or refrigerated conditions manufacture HOHBERGER FONDANT BEATER

Back Suggested readings

• The Science of Sugar Confectionery by W. P. Edwards

• Modern Technology of Confectionery Industries with Formulae & Processes by Minni Jha

• Sugar confectionery manufacture edited by E. B. Jackson (1990)