1 SCI LECTURE PAPERS SERIES HYDROGENATED FATS FOR CONFECTIONERY AND ICE CREAM USE PM Clough Karlshamns Ltd, 220 Wincolmlee, Hull HU2 0PX, UK © 1998 All rights reserved ISSN 1353-114X LPS 0095/98] Key words Hydrogenation, CBAs, Trans Introduction The use of hydrogenated fats in confectionery and ice cream applications is widespread; for the purposes of this paper it is intended to concentrate on their use as Cocoa Butter Alternatives, as filling fats in both Fat and Sugar based confectionery fillings and to briefly cover their use in various ice cream applications. Cocoa butter alternatives Cocoa Butter Alternatives can be split into three groups based upon their raw materials and the processes involved. Cocoa butter alternatives Tempering fats Non-tempering fats CB/CBE CBR CBS Crystal form b b´ b´ Main fatty acids C16/C18 C16/C18 C12 Process fractionation fractionation, hydrogenation fractionation, hydrogenation Compatibility 0–100% 0-20% 0–5% with cocoa butter Cocoa Butter Equivalents are produced by blending exotic fats and usually fractionated Palm Oil, the hydrogenation process as such is not involved in their manufacture; it is however a key processing technique in the manufacture of Cocoa Butter Replacers and Cocoa Butter Substitutes. Cocoa butter replacers CBRs are based upon hydrogenated non lauric fat systems, Soya, Palm, Rape blends, premium grade products being subsequently subjected to a fractionation process. In the production of economy CBRs the role of the hydrogenation process is to ‘steep harden’ for example a rape/palm blend by promoting the formation of trans fatty acids and changing the fatty acid composition from comprising predominantly C18:2cis and C18:1cis to mainly C18:1trans. http://sci.mond.org/lps 2 LPS 0095/98 Processing rape-palm oil economy CBRs Changes in fatty acid composition Initial blend CBR C16:0 20.0 20.0 C18:0 2.8 6.0 C18:1 cis 52.5 15.0 C18:1 trans 0.0 hydrogenation 55.0 C18:2 cis 16.0 1.0 C18:2 trans 0.0 2.0 C18:3 6.0 0.5 C20:0 0.6 0.6 C22:0 0.2 0.2 The result of this on the melting profile of the fat blend is shown in the comparison of the melting profiles of the two blends. Processing rape/palm oil economy CBRs Changes in solid fat content 100 Initial Blend 80 CBR 60 % Solids 40 20 HYDROGENATION 0 10 20 25 30 35 40 Temperature ºC A premium grade CBR would be created by a subsequent fractionation of the hydrogenated product to further increase the relative concentration of C18:1trans fatty acids, resulting in an altogether harder and more steeply melting fat. ISSN 1353-114X http://sci.mond.org/lps LPS 0095/98 3 Processing soyabean oil for premium CBRs Changes in fatty acid composition Soya oil CBR C16:0 11.2 11.0 11.0 C18:0 4.1 16.0 12.0 C18:1 cis 21.7 17.0 – C18:1 trans – hydrogenation 53.0 fractionation 70.0 C18:2 cis 53.9 – – C18:2 trans – 1.1 5.0 C18:3 cis 7.5 – – C20:0 0.4 0.4 0.3 C22:0 0.5 0.4 0.4 Processing Soyabean Oil for Premium CBRs Changes in solid fat content 100 FRACTIONATION 80 % hard SBO 60 Solids HYDROGENATION hard & fract. SBO 40 20 0 10 20 25 30 35 40 Temperature º C Cocoa butter substitutes In contrast to CBRs, Cocoa Butter Substitutes are based upon lauric fat systems normally Palm Kernel Oil. Again the economy products are produced via a straight hydrogenation in which this time the objective is not the creation of trans isomers but rather the saturation of C18:1 and C18:2 fatty acids to C18:0. http://sci.mond.org/lps ISSN 1353-114X 4 LPS 0095/98 Processing Palm Kernel Oil for CBSs Changes in Fatty Acid Composition HYDROGENATION 50 50 % Palm Kernel Oil % Hard PKO 40 40 40 30 30 FR 20 20 AC 10 10 TI 0 0 ONA C8:0 C10:0 C12:0 C14:0 C16:0 C18:0 C18:1 C18:2 C8:0 C10:0 C12:0 C14:0 C16:0 C18:0 C18:1 C18:2 60 60 % % 50 50 TI ON PK Stearine Hard PK Stearine 40 40 30 30 20 20 10 10 0 0 C8:0 C10:0 C12:0 C14:0 C16:0 C18:0 C18:1 C18:2 C8:0 C10:0 C12:0 C14:0 C16:0 C18:0 C18:1 C18:2 HYDROGENATION The resulting CBSs can be produced with melting points anywhere between 32°C and 40°C depending upon the degree of hydrogenation. Processing Palm Kernel Oil for CBSs Changes in solid fat content 100 Increasing Hydrogenation PK Oil 80 Hard PKO 35 s 60 olid Hard PKO 378 % S 40 Hard PKO 40 20 0 10 20 25 30 35 40 Temperature ºC ISSN 1353-114X http://sci.mond.org/lps LPS 0095/98 5 In the production of premium grade CBSs the Palm Kernel Oil is first fractionated and then hydrogenated resulting in a very hard, steeply melting fat system with excellent mouthfeel and melting properties. Confectionery fillings For fat based confectionery fillings the both physical and sensoric properties are determined by the fat phase, hydrogenation of both lauric and non-lauric systems results in a wide variety of products with the physical characteristics to meet most requirements. Solid fat content of hydrogenated fats for fat based confectionery fillings 100 Rape/Palm 80 Rape/Palm Palm s 60 d Soya/Palm Palm Kernel % Soli 40 20 0 10 20 25 30 35 40 Temperature ºC In sugar based fillings, e.g toffees, caramels etc the fat has more impact on the structure rather than the hardness of the product; flavour, oxidation, and rancidity stability are its key requiremnts. Again hydrogenation is a key process in the development of these characteristics. Ice cream fats Hydrogenated fats can be used to replace expensive milk fat in ice cream manufacture, palm/hardened palm blends could be used in economy products whilst blends of hardened laurics and non-laurics would be appropriate for more premium quality products. In ice cream coatings hydrogenated lauric non-lauric blends can produce a fat system which combines the necessary low melting point, rapid melting and elasticity with rapid crystallisation and ‘good snap’. http://sci.mond.org/lps ISSN 1353-114X 6 LPS 0095/98 The primary objective of barrier fats is to prevent moisture migration, they re required to be fast setting, flexible, and of low melting point - steep hardened non-laurics can successfully meet these criteria. ISSN 1353-114X http://sci.mond.org/lps.