Was presented during the workshop about Palm Oil and its application. Presented by: Mr. Ahmed Abdelmonem

1. Specialty Fats In Food Industries
Chocolate,Bakery & Ice Cream
28th Septamber 2014, Ahmed Abdel Moniem

2. Outlines
1. Who we are
2. Specialty Fats for Chocolate
3. Specialty Fats for Bakery
4. Specialty Fats for Ice Cream
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3. IOI Group’s controlled integrated supply chain
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Plantations Oleochemical
• The largest
vegetable oil based
Asian oleochemical
manufacturer
• Combined refining
capacity > 750,000
MT
• Global distribution
• 250.000 hectares
• 14 mills with >4
million MT capacity.
12 RSPO certified
• Enhanced
agronomy R&D and
yield management.
IOI Group
• RM 4.1 billion
revenue
• Listed on Bursa
Malaysia stock
market
• 30.000 employees
IOI Loders Croklaan
• Specialist &
leading player in
tropical oils
• Expert in
commodities and
specialties
• 3 million MT
refining capacity

4. Expertise built on rich experience
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5. Expertise built on rich experience
Achievements and Milestones
o Established in 1890 (UK)
o Invented CBE’s and OPO
o Leading the trans fat elimination
o CO-Founded the RSPO
o Regional Creative Studios
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6. Positioned for your success
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Production location
Sales / Regional office
Bulk oil terminal
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Annual turnover > €1 billion
6 production locations / 9 sales offices
3mm MT of refining capacity / Over 1,000 employees
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7. At home in all segments
Confectionery Bakery Spreads Culinary
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Infant
Nutrition
Non
Frying Dairy Foods

8. Specialty Fats for Chocolate

9. Specialty Fats Definition
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Special Applications
Required
Specific physical properties

10. Bar moulded & shell moulded

11. Hollow figures & sugar filled centres
Kinder Surprise (Ferrero)
– The Smart Egg
 Mild chocolate treat with
surprise toy
 Exterior : Milk chocolate
 Interior : White chocolate
After Eight (Nestle)
 Mint fondant enrobed in
dark chocolate
 The invertase ingredient

12. Various enrobed products
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 common chocolate
application
various chocolate coated
centres : biscuits, cakes,
wafers etc.
 could be premium or
economic products

13. Aerated chocolates
Chocolate
Air
 Aero (Nestle)
 Bubbly (Cadbury)
 Airs (Lotte)
Pressure release
Bubble expand
 Bubble centre filled into moulded shell
Subject to licking roller before back casing
 Higher fat content (> 38%)
Micro-aerated chocolate coating
 Aeration level of 10% or more
 Improvement in taste
 Coating layer thicker and more
 Impression of chocolate

14. Chocolate-coated Candy Bars
Holding tank Temper machine Enrobing machine

15. Panned chocolate
 Preglazing
To seal nut surface to prevent
transfer of nut oil
 Chocolate coating
Dark or milk chocolate can be used
Cold air, ~15 oC, < 50% RH
Pan revolving 18 – 22 rpm
Hand panning, spray panning
 Finishing glaze
Syrup glaze, edible shellac glaze
Chocolate has to set completely
before finishing glaze

16. Chocolate Vermicelli
Cool air
Drilled plate
Vermicelli
Conveyer
Rotating
blade
Manufacture of chocolate
vermicelli
 Decoration use in flour confectionery
 Extrusion through a perforated plate
(with recessed holes)
 When using pure chocolate, cooling
is required to prevent friction heat
from destroying the temper
 Vermicelli is then transferred to
panning machine
 Glazed with syrup and colour
Recessed may be added
holes

17. Cocoa Butter Alternatives
Cocoa Butter
Equivalents
Cocoa Butter
Alternatives
Cocoa Butter
Substitutes
Cocoa Butter
Replacer

18. Product Range
COBERINETM
CREAMELTTM
Loders Croklaan
COUVATM
CLSPTM
555/e
Parhi 100
KERME
BISCUITINETM
MARFAT
CARABUTA
BOS
PALM FRACTIONS
DURKEXTM
REVELTM
FRYING OIL
SHORTENING

19. Cocoa Butter Equivalent (CBE)
Based on non-lauric oils
Only six base fats are permitted – Palm Oil,
Illipe, Sal, Shea, Kokum and Mango Kernel
Rich in symmetrical triglycerides of the type
POP, POSt, StOSt
Miscible in any proportion with cocoa butter
Compatible physical properties with cocoa butter
Obtained only by refining and fractionation

20. Melting Profiles of CBE
74
67
46
2
0
80
70
60
50
40
30
20
10
0
20 25 30 35 40
Temperature, ºC
% Solids by NMR
Cocoa Butter
Coberine 608
Coberine 901

21. Cocoa Butter Replacer (CBR)
Based on non-lauric oils (HPO)
Usually fractionated and frequently hydrogenated
(COUVATM  Hydrogenated Palm Olein)
Under the proposed EU Directive (2000/36/EC) CBRs
could not be included in a product called chocolate
A non-tempering fat
Compatible at 20% with cocoa butter and butter fat
(Allow usage of cocoa mass in recipe)
Correctly balanced recipe  Product with excellent
mouldability, good melt, snap and contraction

22. Cocoa Butter Substitute (CBS)
Based on lauric oils (Palm Kernel Oil)
Sometimes fractionated and frequently
hydrogenated
Under the proposed EU Directive (2000/36/EC)
CBSs could not be included in a product called
chocolate
A non-tempering fat
Compatible at a max of 5% with cocoa butter.
Correctly balanced recipe  Product with
excellent mouldability, excellent melt, snap and
contraction

23. Compound Chocolate Based
on CLSPTM
Dark Type Compound
14% Cocoa Powder
32% CLSPTM
7% Skimmed Milk Powder
47% Sugar
Additives:
Lecithin/flavour
Milk Type Compound
6% Cocoa Powder
32% CLSPTM
17% Skimmed Milk Powder
45% Sugar
Additives:
Lecithin / Flavour

24. Specialty Fats for Bakery

25. Bakery Shortening
Eating Quality
•Better Aeration/creaming properties
•Improved volume
•Handling ease
•Good Stability
•All purpose shortening from MP 33-54oC
Product Name TFA % Solid by NMR, typical value
20 oC 25 oC 30 oC 35 oC 40 oC
Shortfat 370 < 1 28 17 11 6 5
Shortfat 420 < 1 35 23 15 11 7
Shortfat 460 < 1 45 32 22 15 10
Shortfat 480 < 1 48 36 26 20 14

26. Bakery Margarine
 80% fat and 16% water
(water in oil emulsion)
 A substitute for butter
 Industrial margarine  functionality
 Wide plastic range with good
creaming properties
Product Name TFA % Solid by NMR, typical value
20oC 25oC 30oC 35oC 40oC
Marfat 060 < 1 33 23 16 10 4

27. Industrial Frying
ROLE OF OIL & FAT
IN FRYING
 Texture
 Fried Food Flavour
 Mouthfeel
 AfterTaste
Conceptual heat and mass transfer
during frying

28. Selection of Frying Oil
Product Name TFA % Solid by NMR, typical value
20 oC 25 oC 30 oC 35 oC 40 oC
DurkexTM 200 < 1 1 0 0 0 0
Palm Olein IV 56 < 1 5 0 0 0 0
Palm Oil < 1 28 15 10 7 4

29. Milk Fat Replacers
Product Name TFA % Solid by NMR, typical value
20 oC 25 oC 30 oC 35 oC 40 oC
BOS 6262 < 1 29 17 11 6 4
BOS 7534 6 30 21 15 8 0
CarabutaTM NH < 1 50 28 16 10 6
CARABUTA TF contains essential
flavor precursors of milk fat.
During cooking, the butter flavor
in CARABUTA TF develops in exactly
the same way as it does when
milk fat itself is used.

30. Sugar Confectionery
 Fat functions as flavor carrier
 Fat acts as lubricant and softener (less sticky product)
 Hard candy (low moisture)  Lauric
 Soft caramel / toffee (higher moisture)  Non Lauric
Product Name TFA % Solid by NMR, typical value
20 oC 25 oC 30 oC 35 oC 40 oC
BiscuitineTM 621 29 58 41 23 9 0
CarabutaTM NH < 1 50 28 16 10 6
CLSPTM 620 6 60 30 10 4 1
CLSPTM 825 3 77 48 17 5 0

31. Non Dairy Creamer
 Formulated based on hydrogenated palm kernel
oil or olein with melting point of 35 – 42 oC
 Higher melting fats required for shelf life, anti-clumping
characteristics, and good dispersion in hot liquid
Product Name TFA % Solid by NMR, typical value
20 oC 25 oC 30 oC 35 oC 40 oC
CLSPTM 826 3 75 50 26 12 5

32. Whip able Toppings
 Formulated based on hydrogenated palm
kernel oil, hydrogenated palm kernel stearine,
or blends of the two
 Easy air incorporation during whipping and give
high solids content required for foam stiffness
Product Name TFA % Solid by NMR, typical value
20 oC 25 oC 30 oC 35 oC 40 oC
CLSPTM 825 3 77 48 17 5 0

33. Ice Cream Mass
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34. Ice Cream Mass
“Ice cream is a frozen dairy food made by freezing a pasteurized mix under
agitation to incorporate air, ensuring uniformity and consistency”

35. Ice Cream Ingredients
Fat
Milk Solids Non Fat
Sugar
Water
Emulsifiers/Stabilizers
Flavouring
Colouring
Fat in Ice Cream
Milk Fat
• Milk
• Cream
• Butter
• Anhydrous Milk Fat
Vegetable Fat
• Palm Oil
• Palm Kernel Oil
• Coconut Oil

36. Fats for Ice Cream Mass
 Not the continuous phase
 5-15% of the fat phase which determines the eating
quality
oHardness
oMeltdown Behaviour
oTexture
oBody
oMouthfeel
oCreaminess
oFlavour Release
Function of fat
oBuilding block for ice cream
structure
oStabilize the air cell structure
oInteraction with protein and
emulsifier
oImportant function during
whipping and churning of ice
cream

37. Fats for Ice Cream Mass
Product Name TFA SMP,oC % Solid by NMR, typical value
20oC 25oC 30oC 35oC 40oC
CLSPTM 625 <1 35 71 42 18 7 2
CLSPTM 710 <1 34 65 37 14 4 0
CLSPTM 720 8 33 65 37 14 4 0
CreameltTM 500 <1 29 45 26 6 1 0
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38. Recipe –Ice Cream Mass
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General Soft serve
Fat 10.0 12.0
Sugar 13.0 15.0
MSNF 10.4 11.0
Dextrose 3.5 -
Corn Syrup Solids - 3.0
Emulsifier/Stabilizers 1.0 0.4
Water 62.1 58.6

39. Ice Cream Coating
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40. Fats for Ice Cream Coating
Represent the continuous phase
40 – 60% of the coating 
determines the eating quality
oHardness
oMeltdown behaviour
oBrittleness
oFlavor Release

41. Recipes – Ice Cream Coating
Ingredients %
Fat 55.0
Alkalized Cocoa Powder 10/12 8.0
Sugar 35.6
PGPR 0.75
Lecithin 0.14
Vanillin Optional

42. 42
Dripping & Drying
Dipping
+ 35 /
+ 45°C
Dripping
time
Drying time
Packaging

43. 43
DRIPPING
DRYING

44. Let’s create together
Thank you
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