Adam Lechter: Resident Course in Confectionery Technology

Compound Coatings
&
Cocoa Butter Alternatives
Adam Lechter
Resident
Course in
Confectionery
Technology
What are “Compound Coatings”
• Formulations that may resemble

chocolates in composition but for one or
more reasons do not meet established
standards of identity (SOI) for chocolate
products.
• In many “compounds,” some or all of
the cocoa butter is displaced by
alternative vegetable fat(s).
• In others, no ingredients derived from
cacao are used.
• In others, certain other ingredients or
ingredient levels are used that are
inconsistent with present SOI.
Resident Course in Confectionery Technology
Confectionery Coating Types
• Compounds (examples) • Chocolate

⇒ Cocoa based ⇒ Milk
⇒ Liquor based ⇒ Bittersweet/
⇒ Whey containing Semisweet
⇒ Sugar-free ⇒ Sweet
⇒ Pastels (pink, yellow, etc.) ⇒ White
⇒ Peanut, butterscotch, fruit
⇒ Frozen dairy dessert low melt
coatings or inclusions
⇒ Low calorie “fats”
≈ 1/3 size of chocolate market

Compound Product Applications
• Enrobing
• Bottoming
• Fillings
• Decorations
• Striping
• Molding
• Frozen dairy dessert coatings
• Panning (fruits, nuts, etc.)
• Inclusions (chips, chunks, wafers)
• Barrier coatings

Properties of a Good Coating
• Rapid melt in the mouth

• Dry touch
• Pleasing appearance
• No off-flavor
• Appealing consistency
• Acceptable shelf-life
• Proper crystallization
characteristics

Fat Function is Critical
• In all coating formulations, vegetable fat

provides the continuous matrix in which all
other ingredients contributing to flavor,
aroma, texture and color are uniformly
dispersed.
• This coating fat system must ideally melt in
the mouth rapidly and completely to
maximize flavor release and enhance
mouth-feel.
• Must crystallize properly.
Why is cocoa butter so great ?
• Very high solid fat content at room

temperatures
• Melts rapidly and completely in the mouth
(not in your hand!)
• Compliance with Standards of Identity
• Not recognized as a source of trans-fat

Fats and Oils in Confections
• Continuous phase in coatings & centers
• Roasting media for nutmeats
• Release agent on equipment & wrappers
• Carrier for flavors, colors, etc.
• Moisture barrier
• Fat migration barrier
• Gloss enhancing agent
• Fats found within various ingredients such as
nuts, seeds, and milk powders.
! And consider the fats and oils that might be present in
non-confections coated with or containing compound
coatings.

Cocoa Butter Melting Profile
90 hardness / snap
80
70
heat flavor release
60 resistance cooling sensation
% solid fat
50
40
30
20
no waxy mouth-feel
10
0
50 60 70 80 90 100 110
temperature °F

Why use alternatives to Cocoa Butter ?
• Ease of processing
• Compatibility with other fats
• Textural options
• Temperature tolerance (melting range
options)
• Economics (savings / less price volatility)
• Freedom from Standards of Identity

Some of non-SOI the possibilities…
• Alternative to cocoa butter employed

• Non-nutritive and/or polyol sweetener
employed
• Other non-complying ingredient(s) used
– chocolate, milk or butter flavors
– whey powders
– fortified with added nutrients
– overuse of emulsifiers
– carob powder

Cocoa Butter Alternative Fats CBA
• Cocoa Butter Equivalents Æ CBE

– Illipe, Shea, Sal, Mango Kernel, Palm
• Cocoa Butter Replacers Æ CBR

– Soybean Oil, Cottonseed, Palm
– a.k.a. “non-laurics”
• Cocoa Butter Substitutes Æ CBS

– Palm Kernel & Coconut Oils
– a.k.a. “laurics”

Common Vegetable Fatty Acids
• C 6:0 Caproic • C 16:0 Palmitic

• C 8:0 Caprylic • C 18:0 Stearic
• C 10:0 Capric • C 18:1 Oleic
• C 12:0 Lauric • C 18:2 Linoleic
• C 14:0 Myristic • C 18:3 Linolenic
shorter chains longer chains
lauric fats non-lauric fats

Non-Lauric vs. Lauric Fats
• Non-Lauric • Lauric
– Soybean – Palm Kernel
– Cottonseed – Coconut
– Palm
– Canola
– Corn
– Sunflower
– Peanut

Big decision...
Choice of CBA will help determine:*

• Flavor release
• Flavor stability
• Initial gloss
• Gloss retention
• Hardness and snap
• Rate of crystallization / contraction / mold release
• Compatibility with other fats
• Temperature tolerance
• Nutrition (e.g. trans fat levels)
* All in the context of the specific application,
related processing and handling.

CBE’s / CBE Based Compounds
• Triglyceride composition very similar
to cocoa butter (i.e. SUS structure)
• Must be tempered
• Not presently permitted under U.S.
chocolate standards of identity
[Are permitted in the European Union
and selected other markets at 5%
substitution level in “chocolates”
(about 15% on a fat basis)]
• Compatible with cocoa butter in nearly
any mix ratio.

Mixing CBE with Cocoa Butter
100 10°C 100
90 20°C 90
80 25°C 80
Solid Fat Content (%)
27.5°C
70 70
60 60
50 50
30°C
40 40
30 30
20 32.5°C 20
10 10
35°C
(double-y)
0/100 20/80 40/60 60/40 80/20 100/0 %
Cocoa Butter / CBE (example)

CBR and CBS Properties
• Much different triglyceride
composition than cocoa butter.
• Most crystallize directly into a
fairly stable β’ crystal form.
• Many are known to do well without
tempering*.
* Tempering decisions must be taken with careful

consideration to the application and processing
capabilities.

CBR and CBS Processing
• Refining, Bleaching and Deodorization

• Plus one or more of the following:
– Hydrogenation
– Interesterification
– Fractionation

CBR (Non-Lauric) Processing
To produce suitable CBRs from oils like

soybean oil, cottonseed oil and palm oil,
manufacturers often use partial
hydrogenation and sometimes
fractionation processes.

Triglyceride
SATURATED FATTY ACID

G
C 18:0 Æ m.p. = 156°F
L
Y MONO -UNSATURATED FATTY ACID
C
C 18:1 Æ m.p. = 55°F
E
R POLY -UNSATURATED FATTY ACID
O C 18:2 Æ m.p. = 23°F
L

Hydrogenation
H2
+
Catalyst
tra ns
tra ns
c k !
yu
tristearin Æ m.p. = 160°F

Hydrogenation
unsaturated bond saturated bond
“cis” orientation “trans” orientation

(55°F m.p.) (113°F m.p.)

Trans Isomer Levels and Regulations
• You should be aware that trans fatty acid
levels in some partially hydrogenated CBR
coating fats may be as high as 50 to 60% of
total fatty acids present.
• FDA finalized new fat labeling regulations

which require “trans fat” to be included on
nutritional information panels when present at
levels greater than 0.5 grams/serving.
• CFIA (Canada) mandates labeling under
certain circumstances. Best explanation can
be found at:
www.inspection.gc.ca/english/fssa/labeti/inform/20050914e.shtml#2

Fractionation
Confectionery fat candidates may only partially
crystallize at room temperatures. With the aid
of pressure, solvents, centrifugation, and/or
filters, a largely liquid oil portion may be
separated from a more solidified fraction.
xx x x x x x x stearin
x x o x ox x o x xo x x (solid)
o o o
o x x
x o o oo o o o o olein
o
x o xo x o o xo o o x o o (liquid)

Typical CBR’s vs. Cocoa Butter
90
80
70
60 little “snap”
% solid fat
50
40
30 “waxy”
20 mouth-feel
10
0
50 60 70 80 90 100 110
temperature °F
Hyd Soya-Cotton Hyd/Frac Soya-Cotton Cocoa Butter

CBR Coating Summary
Compared to Chocolate (typically)…

• Less “snap”; more flexible
• Very limited contraction on crystallization
(mold release issue)
• Slower melt-away & flavor release
• Non-tempering
• Good gloss retention & shelf-life
→ Probably high in “trans” fatty acids

CBR Compatibility w/Cocoa Butter
Reportedly, some CBR fats, produced

from both partial hydrogenation and
fractionation processes, can “tolerate”
up to 20%* cocoa butter.
*Significant softening occurs along with

prolonged setting times and reduction in gloss
and gloss-stability.
Note: CBR based compounds may be good

candidates when common systems are used for
both chocolate and compound coatings.

Mixing Fractionated CBR with Cocoa Butter
Solid Fat Content (%)
Cocoa Butter / Frac. CBR

Examples of CBR Based Coatings
• Milk Chocolate Flavor • Dark Chocolate Flavor

→ Sugar → Sugar
→ CBR (non-lauric) → CBR (non-lauric)
→ Nonfat dry milk → Cocoa
→ Whey → Chocolate liquor
→ Cocoa → Monoglycerides*
→ Monoglycerides* → Sorbitan mono-
→ Sorbitan mono- stearate*
stearate* → Lecithin
→ Lecithin → Vanillin
→ Vanillin
*Sometimes added to improve contraction and release properties.

Other additives may also prove helpful…

CBR Compound Applications
• Cookie and cracker coatings

• Economy baking drops / inclusions
• High bulk / lower-cost candy bar coatings
• Coatings for spongy substrates since
CBR coatings are likely less brittle than
chocolate

Products w/CBR Based Compounds
Non-Laurics
R ’s
CB
u se
e r
n g
l o
n o
n y
Ma
Winter 2001/2002

CBS (“Lauric”) Processing
Cocoa Butter Substitute fats are produced

mainly from palm kernel oils with the use
of processing techniques such as
hydrogenation, interesterification, and
fractionation.
Note: CBS compound coating fat systems
may contain small quantities of hydrogenated
soybean, palm or cottonseed oils to modify
crystallization properties and/or melting range.
Many times these fats are nearly fully
saturated.
Interesterification (Rx)
A A A A A A
A A B A C B
A B A C A C
A C B B B B B B
B B B B A B C C
A C B A B C B A
(w/catalyst
or enzyme) C C C C C C
C C A B C A
C A C C B B
Interesterification is most often used in combination

with hydrogenation to achieve desired melting ranges.

Selected CBS’s vs. Cocoa Butter
100
great
90 snap
80
70
60
50
% solid fat
40
30
20 some
waxiness
10
0
50 60 70 80 90 92 94 100 102
temperature °F
Cocoa Butter Hydro/Rx PKO Hydro/Frac PKO Non-Hydro/Frac PKO/Palm

CBS Coating Summary
• Run tempered or non-tempered

• Rapid crystallization properties
• Good mold and belt release
• Hard and dry to touch
• Good flavor release & mouth feel
• Good gloss retention / shelf-life
* All in the context of well suited applications and related

processing and handling. Only the end-user can determine
performance in their application(s)

Mixing CBS with Cocoa Butter
Eutectic Profile - Cocoa Butter / CBS
100
• CBSs (lauric fats) are not 90
% Solid Fat Content (NMR)

compatible with cocoa 80
10°C
butter.
70
20°C
60
• Efforts are usually made 50
40
25°C
to hold cocoa butter levels 30

30°C
to less than 5% unless 20 35°C
softening is desired 10
(e.g.melt-away centers). 0
0/100 20/80 40/60 60/40 80/20 100/0
%Cocoa Butter / %FPKO CBS

Small, well packed, stable formation...

Examples CBS Based Coatings
• Milk Chocolate Flavor • Dark Chocolate Flavor

→ Sugar → Sugar
→ CBS (lauric) → CBS (lauric)
→ Nonfat dry milk → Low Fat Cocoa*
→ Low Fat Cocoa* → Monoglycerides
→ Monoglyceride → Lecithin
→ Lecithin → Vanillin
→ Vanillin
* Remember, many say it’s best to keep cocoa butter level below
5% on fat basis when concerned about bloom and/or softening.

CBS Compound Coating Applications
For standard quality CBS compounds
→ Bakery & confectionery products in which coating
eating quality is not a dominant factor in defining
overall eating quality.
For premium fractionated CBS compounds

→ Pastel or chocolate flavored coatings for molding or
enrobing as well as chocolate and other flavored chips.
Used when eating quality must be comparable to
cocoa butter (chocolate).
Both standard and premium CBS compounds

→ Bakery and confectionery products within which trans
fat content is a concern to manufacturer/consumer.

Products w/CBS based compounds
Laurics
Winter 2001/2002

Products w/CBS based compounds
Laurics
More recent sampling

Hydrolysis (soapy taste)
H2O
+
PROMOTER
Diglyceride
Triglyceride
Free Fatty Acid

Frozen Dairy Dessert Coatings
Sometimes called frozen novelty coatings or

pail coatings, or ice cream coatings…
• Typically contain up to 60% fat
• Must crystallize (“dry”) quickly
• Must melt in the mouth even at low temps.
• Are most often based upon coconut oil but
may contain lesser amounts of non-lauric
fats used to both depress melt points and
reduce tendency to fracture on consumption.

Some Compound IC Coatings
Example 1 Example 2 Example 3 Example 4 Example 5
Coconut Oil (24C) 10.3% 64% 57% - 33%

Soybean Oil (35C) - - - 49% -
Peanut Oil 4% - - - -
Sugar 36.0% 30% 27% 46.5% 52%
Chocolate Liquor 10.9% - 6.2% - -
Cocoa Butter 19.6% - - - -
Cocoa Natural - 3.3% - 4.0% 2%
Cocoa Alkalized - 1.9% - - 12%
Milk Powder 18.2% - 8.0% - -
Lecithin 0.5% 0.5% 0.5% 0.5% 0.5%
Flavorings 0.5% 0.3% 1.3% - 0.5%

Handling & Working
with Compound Coatings

Melting ( Blocks / Wafers )
• Set melting kettle to achieve no more than 130-135ºF
with gentle agitation on.
• Add 10# blocks (broken!) or wafers slowly at first (e.g.
start with only 50 lbs.) being sure to completely melt
entire amount before adding more.
• Add additional increments (e.g. 50 lbs.) while assuring
complete melting before each successive addition.
• Follow this procedure until a satisfactory base of melted
coating is established (e.g. tank ¼ full)
• Increase weight of addition (100-150 lbs./addition) while
still assuring complete melt before next add.
• As tank nears filling, addition rate may be increased
cautiously. (may begin dropping temperature to 115-120F)
• Melted coating may be transferred from melting tank to
enrober surge tank for temperature conditioning.
* The most desirable temperature ranges and timing must be determined by end-user
in the context of specific applications, equipment features and handling requirements.
Enrobing & Molding Temperatures*
Typical ranges in relation to fat phase melting points:
Lauric (CBS) Non-Lauric (CBR)

-2 to +1°F +2 to +4°F
Note: “Fat phase” will include the CBA fat + any cocoa
butter + lecithin + other fat soluble ingredients such
as certain emulsifiers or crystallization modifiers.
* Based on careful end-user observations. The most desirable temperature
ranges must be determined by end-user in the context of specific
applications, equipment features and handling requirements.

Cooling Tunnel Conditions*
Lauric (CBS) Non-Lauric (CBR)
Initial Zone 45-53°F 40-50°F
Center Zone 40-45°F 37-42°F
Final Zone 55-60°F 55-60°F
* Relative relationships; specific conditions depend upon finished

product characteristics and equipment limitations.

Cooling Tunnel Conditions
Temperature ºF
65
60
55
50
45 Laurics
40 Non-Laurics
35
Initial Zone Center Zone(s) Final Zone

Contraction/Release Properties
Contraction characteristics on crystallization:
• Non-Lauric Æ Poor - Fair

• Lauric Æ Good - Very Good
• Cocoa Butter Æ Very Good

Cocoa Butter Tolerances
%Cocoa Butter Tolerance
CBE fats up to 100%

Non-lauric CBR up to 20%*
Lauric CBS up to 5%
* Not without significant consequences

Fat Levels
Other things being equal including ingredients

and particle size distribution, less lauric fat is
usually required than non-lauric to achieve
comparable rheological properties.

Modifiers or Improvers
Lecithin, monoglycerides, sorbitan esters, high

melting fats and other ingredients are often
employed in compound coatings for one or more
of the following reasons:
– Influence rheological properties (e.g. PGPR)
– Modify crystallization rate
– Increase melting point
– Improve gloss stability
– Enhance contraction and release
Note: Every situation is different! Tests by end-users

must determine final ingredient needs.

Storage
• Conditioning
→ 24-48 hours (common)
→ Ensure crystallization in stable forms
and adequate dissipation of heat of
crystallization.
• Cool & Dry Environment
→ 65-70ºF (18-21ºC) [some exceptions]
→ <50% R.H.
• Odor-Free Environment !

How to Choose a Coating System
• Type of application?
• Type of product?
• Performance characteristics
desired?
• Specifications / labeling issues?
• Shelf-life requirements?
• Target market / distribution
issues?
• Processing equipment resources?
• Economics?
Case Study I – Donut Coating
• Conditions:
9 CBS coating w/108°F mpt.
9 Low viscosity for thin coat
9 Enrober @ 116°F (no temper)
9 Tunnel @ 41-43°F; one zone in 1 min. 45 sec.
• Observations:
9 Dull coating at end of tunnel
9 Duller and bloomed coating in distribution
9 Blocking of donuts in package with wet
smearing noted on plastic sealing wrap

Case Study I – Donut Coating
• Solution:
9 Addition of 1+% higher mpt. mono-glyceride
9 Increase level of palm stearine
9 Enrober temp. no change (operator
resistance)
9 Cooling tunnel no change (not possible)
9 Enrober room dehumidified
Why did these changes solve the problem?

Case Study II – Nut Bar Coating
• Conditions:
9 Standard CBS 102 °F mpt. compound
9 Center included ground peanuts / sugar
9 Bars enrobed successfully
• Observations:
9 In storage and distribution coating showed signs
of softening including tacky feel and
smearing within wrap. Some
coating was easily dislodged
w/handling.

Case Study III – Nut Bar Coating
• Solution:
9 Coating fat changed to hydrogenated,
fractionated palm kernel oil blend.
Why?

Perhaps a helpful reference…
• Importance of Fats
• What is a fat?
• Chemical Composition of Fats
• Fatty Acids
• Nutritional Aspects of Fats & Oils
• Factors Affecting Physical
Characteristics of Fats & Oils
(including polymorphism)
• Processing
• Reactions of Fats & Oils
• Products Prepared from Fats & Oils
(including “Hard Butters”)
• Trends in Fat Consumption
• Glossary
• Common Test Methods
Sensory Comparison
Chocolate & Confectionery
Bill Vlach
2008 Resident
Course in
Confectionery
Technology
Chocolate
Bunny Chocolate
(commercial – milk)
• Generally minimum
levels of chocolate
liquor (10%) and milk
(12%)
• Coarser particle size
(0.0011+)

Premium Milk Chocolate
• Higher levels of milk (16-24%+)
• Conched longer and/or perhaps
at higher temperatures to
develop flavor
• Liquor level in balance with milk
impact
• Finer particle size (less than
0.0009”)

Premium Bittersweet Chocolate
• Variety of chocolate liquor features including
country of origin, processing conditions
(roasting and alkalization), and liquor levels
(“%cacao”)
• Sometimes milk fat is added for handling and
to aid in control of bloom
• Particle size less than 0.0009”

Bittersweet Chocolate Chips
• Liquor content 35%-42%
• Dextrose added for baked goods
• Particle size 0.0009+
• Common applications
Premium Bittersweet Chocolate Chips

• Similar to Premium Bittersweet Chocolate
• Larger size Chips/Drops
• Particle size less than 0.0009
• Indulgent applications

White Chocolate Coating & Drops
• Fitting standards of min. 14% milk, min.
3.5% milk fat, min. 20% cocoa butter,
max. 55% nutritive carbohydrate
sweetener
• Mild, milky flavor with degrees of
chocolate flavor

Confectionery
White Confectionery Coating
w/Fractionated Palm Kernel Oil
• Similar flavor characteristics to white chocolate

• Possible added coloring to enhance “whiteness”

Confectionery Coating
w/Hydrogenated Palm Kernel
• Compare mouth feel to

chocolate or fractionated PK
• Chocolate flavor with cost advantages
• Increased chocolate flavor limited by increased cocoa
butter from cocoa

w/Hydrogenated Soy/Cottonseed
• Compare the texture to chocolate and palm

kernel
• Advantages/disadvantages of
soy/cottonseed. Trans fat content may be
an important factor.
• Type of oil allows use of chocolate liquor
for flavor options and/or increased cocoa

w/Hydrogenated Fractionated Palm Kernel
• Compare mouth feel and flavor release to other

chocolate flavored products.
• Compare with SOI chocolate.
• The ease of demolding allows use in small, delicate
items.

Non-Hydrogenated & Fractionated
Palm Kernel and Palm Oils
• No trans; No hydrogenation
• Direct replacement for hydrogenated and/or
partially hydrogenated palm kernel and palm
oils
• Texture of coating and flavor release similar to
the above fats replaced

Our Thanks!

Adam Lechter: Resident Course in Confectionery Technology

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Compound Coatings

• Formulations that may resemble

• Compounds (examples) • Chocolate

≈ 1/3 size of chocolate market

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

• Rapid melt in the mouth

Resident Course in Confectionery Technology

• In all coating formulations, vegetable fat

• Very high solid fat content at room

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

• Alternative to cocoa butter employed

Resident Course in Confectionery Technology

• Cocoa Butter Equivalents Æ CBE

• Cocoa Butter Replacers Æ CBR

• Cocoa Butter Substitutes Æ CBS

Resident Course in Confectionery Technology

• C 6:0 Caproic • C 16:0 Palmitic

shorter chains longer chains

lauric fats non-lauric fats

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Choice of CBA will help determine:*

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

* Tempering decisions must be taken with careful

Resident Course in Confectionery Technology

• Refining, Bleaching and Deodorization

Resident Course in Confectionery Technology

To produce suitable CBRs from oils like

Resident Course in Confectionery Technology

SATURATED FATTY ACID

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

“cis” orientation “trans” orientation

Resident Course in Confectionery Technology

• FDA finalized new fat labeling regulations

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Compared to Chocolate (typically)…

→ Probably high in “trans” fatty acids

Resident Course in Confectionery Technology

Reportedly, some CBR fats, produced

*Significant softening occurs along with

Note: CBR based compounds may be good

Resident Course in Confectionery Technology

Solid Fat Content (%)

Cocoa Butter / Frac. CBR

Resident Course in Confectionery Technology

• Milk Chocolate Flavor • Dark Chocolate Flavor

*Sometimes added to improve contraction and release properties.

Resident Course in Confectionery Technology

• Cookie and cracker coatings

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Cocoa Butter Substitute fats are produced

Interesterification is most often used in combination