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ers used are simplified to help you understand things easier. For your use, talk to your supplier and find out exactly what is in the raw material you are using. Ingredients Water — 170.0 g No, we’re not going to break down the water but just make a few comments. Its level before, after and at each stage of the process can have a lot of influence.With other ingredients, you may be off a percent or two and it will modify the product some if it does anything at all. If you are off a percent or two on water, the following could happen: • The caramel could grain when you don’t want it to or not grain when you do. • It could be too hard or too soft. • It could be less stable due to the water activity being too high, where you have problems with micro if sealed or its tendency to dry out if not; or too low, with problems of it picking up moisture and requiring more expensive packaging. As an ingredient before cook, a starting point for how much water to add is about one-third the level of sugar, to help make sure all the sugar is dissolved. This of course will change due to the process you use. For after cook, it’s the final texture you want that determines how much water is left. For each of the processing stages, it’s how fast or slow you want to develop the color and flavor or the when and how it will or will not grain. Don’t forget about the water quality. You write specifications and have quality control checks for all of your ingredients, yet even with the importance of the water in your recipe, how many of you know what is in your water? The best example is if it’s too acidic you may need to use a buffer salt to prevent the milk proteins from denaturing or precipitating out, Sugar, granulated — 454.0 g Sugar we can break down.Although for this exercise you Caramel — Raw Materials and Formulations Breakdown of Sugar, Granulated Sugar . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454.0 g Sucrose (99%) . . . . . . . . . . . . . . . . . . 449.5 g Invert (1%) . . . . . . . . . . . . . . . . . . . . . . . . 4.5 g Dextrose (50%) . . . . . . . . . . . . . . . . . . . . 2.25 g Fructose (50%) . . . . . . . . . . . . . . . . . . . . 2.25 g Figure 2 Breakdown of Corn Syrup 42 DE/A Corn syrup . . . . . . . . . . . . . . . . . . . . . . . . . . . 369.0 g Dextrose (18% dry, 14.5% wet) . . . . . . . 53.5 g Maltose (14% dry, 11.0% wet) . . . . . . . . 40.6 g Polysaccharides (68% dry, 54.5% wet) 201.1 g Water (20% wet) . . . . . . . . . . . . . . . . . . . . . .73.8 g Figure 3 can assume no moisture, you can also assume there will be some inversion. For this paper, we’ll keep the numbers simple and assume 1 percent inversion. So now our recipe looks like Figure 2. Some confectioners prefer using brown sugar to partially replace the sucrose, developing a very nice change to the overall flavor. When you do, be sure to get its breakdown. It will contain some invert sugar and ash, with the invert sugar affecting texture, solids of the syrup phase and water activity, while the ash affects processing (foaming) and both affect the Maillard reaction. Corn syrup, 42 DE/A— 369.0 g Corn syrup can also be broken down more. For the sake of simplicity, we’ll break it down only to DP1, 2, 3+ (DP1–dextrose, DP2–maltose, DP3+–higher saccharides) and its water level. The breakdown percentages are simplified to demonstrate the idea (Figure 3). Again, check with your supplier for exact numbers.There are many corn syrups available, with different ranges of the components and even with different components. Sweetened condensed whole milk— 312.0 g Now to break down the scwm.To keep this part simple we’ll break it down to ➤ You write specifications and have quality control checks for all of your ingredients, yet even with the importance of the water in your recipe, how many of you know what is in your water? 57 th PMCA Production Conference, 2003 25
Caramel — Raw Materials and Formulations So many things about the milk can have an effect. The differences in the raw milk itself, how it was processed, stored and reconstituted, all have their effect, mostly due to protein quality. Breakdown of Sweetened Condensed Whole Milk Scwm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312.0 g Sucrose (61.1% dry, 44.0% wet) . . . . . 137.3 g Butterfat (11.8% dry, 8.5% wet) . . . . . . . 26.5 g Lactose (14.6% dry, 10.5% wet) . . . . . . . 32.8 g Protein (12.5% dry, 9.0% wet) . . . . . . . . 28.1 g Water (28% wet) . . . . . . . . . . . . . . . . . . . . . 87.3 g Figure 4 the sugar, fat, lactose, total protein and water levels.The numbers again are examples (Figure 4). Look at the sugar in the scwm, it’s almost a quarter of all the sucrose in the caramel recipe and most of the solids of the ingredient. Remember to check with your supplier for exact numbers. There are many other forms of milk that can be used or even different components from milk such as just adding casein or whey.The casein mostly affects texture by adding body and the whey proteins add color and flavor.They could be used to cut costs or modify your texture or flavor. Again, break them down, for example, for the lactose usually found in the whey. If adding more casein or whey, break down the protein above so you know how much you’re starting with. So many things about the milk can have an effect. The differences in the raw milk itself, how it was processed, stored and reconstituted, all have their effect, mostly due to protein quality. You need to find which of the differences will affect your caramel and then you need to control them. Partially hydrogenated vegetable fat — 184.0 g We won’t break the fat down, but here are the critical numbers of the fat: • The melt point — the higher the melt point, the better the stand-up, but be careful going above 92°–95°F as it can start to give it a waxy texture and flavor. • The solid fat index (sfi)—this will let you know how sharp a melt curve you will have. This can influence the flavor release. Other factors in deciding are resistance to oxidation and even how the fats are added. Blending several fats before emulsification can yield overall softer fats due to eutectic effect. Salt — 14.0 g The salt is used primarily to enhance flavor. Soy lecithin — 2.5 g The soy lecithin is an emulsifier, ensuring a good dispersion and homogenization of the fat. Other emulsifiers can be used to help with specific needs of your caramel. For example, gms can be used to help with stand-up or to help with cutting a caramel that is sticky. Talk to your suppliers to determine which are best for your needs. Don’t forget that the milk proteins also help in emulsification and in some cases may be all you need. Just make sure you have the level and type of emulsifier correct. If too much, you’re wasting money and it could even contribute to off flavor or texture and if too little, it could oil out. Other ingredients It is common to use carbonates, phosphates or other buffers to adjust the pH of your caramel. If the pH is too low, below the isoelectric point of the milk proteins (~4.6), the proteins will precipitate.As the pH rises, you affect the rate of the Maillard reaction, but if it is too high your flavor quality decreases.A good starting point is a pH between 6 and 6.5. You can use other ingredients to modify texture and flavor, such as various nutmeats and vanilla or vanillin. Starches or other thickeners can be used to modify product texture and your process. Putting it all Together Now rewrite your recipe and turn it into a formula. Our recipe turns into Figure 5. ➤ 26 57 th PMCA Production Conference, 2003
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