BAKERY BEVERAGES AND CONFECTIONARY

TECHNOLOGY: REPORT

TOPIC: CHEWY TOFFEE

DONE BY
TAMIL SELVAN – URK17FP094
SANTHOSH – URK17FP095
INTRODUCTION:

Toffees are high-boiled products containing brown sugar, glucose

sugar or invert sugar and fats, usually butter. These products have moisture
level less than 5%. Most toffees are chewable rather than glassy. Toffees
have lower moisture content than caramel and having harder texture. As
toffees normally have dispersed fat in them, they are emulsions. Toffees
are nearest the oil-in-water category of emulsions since water itself is only
a minor constituent of a finished toffee; the continuous phase of a toffee is
a sugar and glucose syrup mix. In these products the crystalline or grainy
texture developed during processing and structure is stabilized before
product is packed.

HISTORY:

The origin of the word “toffee” seems to be lost in time although it

might be derived from “taffy”, a dialect word for “sticky”. The
development of Mackintosh’s toffee is regarded as important as it was said
to combine the attributes of soft American caramel with English hard
toffee. The resulting chewy product had the advantage that it could be sold
all around the world without refrigeration. Because of this history, in the
UK at least, toffee and caramel seem to be used interchangeably, and
toffee is used to refer to products ranging from viscous liquids to hard
sugar glasses.
INGREDIENTS:

The basic ingredients used in the production of toffee are:

i. Sugar (sucrose)

ii. Glucose syrup

iii. Milk Protein
iv. Fat
v. Salt
vi. Water
vii. Other additives e.g. colour, flavour etc.

SUGAR:
Sugar is an important ingredient in most confectionery products,
where its sweet taste is only one of the reasons for using it; equally
important is its ability to enhance other flavours.

In confectionery production, not only sugar, but also inverted sugar

(equal quantities of glucose and fructose) as well as various types of
glucose syrup are used. Inverted sugar is primarily added to prevent
crystallisation in marshmallows. Glucose syrup is used to balance the
sweetness, but in some cases also to control crystallisation.

GLUCOSE SYRUP:
Glucose syrup, also known as confectioner's glucose, is
a syrup made from the hydrolysis of starch. Glucose is
a sugar. Maize (corn) is commonly used as the source of the starch in the
US, in which case the syrup is called "corn syrup", but glucose syrup is
also made from potatoes and wheat, and less often
from barley, rice and cassava.

Glucose syrup containing over 90% glucose is used in

industrial fermentation, but syrups used in confectionery contain varying
amounts of glucose, maltose and higher oligosaccharides, depending on
the grade, and can typically contain 10% to 43% glucose. Glucose syrup is
used in foods to sweeten, soften texture and add volume. By converting
some of the glucose in corn syrup into fructose (using
an enzymatic process), a sweeter product, high fructose corn syrup can be
produced.

MILK PROTEIN:
The role of milk proteins in the modification of caramel texture was
investigated m this study. Effects of homogenization pressure,
homogenization order, fore warming temperature, fore warming the, and
sugar/protein concentration on response variables relevant to milk protein
functionality were investigated. Milk proteins affected the texture of
caramel(p<0.05).

FAT:
Fat in caramel aids richness to flavour and improves textural
properties. The presence of fat makes significant contribution to the
texture, chewing characteristics, colour and flavour of caramel. The fat
should have a balance between butter to contribute flavour and texture and
hardened plant oil (hydrogenated fat) for stability. Fat, generally, used in
caramel is from dairy source and vegetable fats such as coconut oil,
hydrogenated vegetable oils, and partially hydrogenated palm oil (HPO) or
palm kernel oil (HPKO). The fat also acts as lubricants, and phospholipids
present in milk fat act as emulsifiers. The level of fat in caramel ranges
from 5 to 20%, typically at 10 to 12%. Low fat levels tend to produce
caramels that are sticky and difficult to chew while a high fat product
without the addition of an emulsifier will lead to 'oiling out' on the surface
of the confection. The melting point of fat source used is very important in
terms of functionality in product. The melting point of fat should range
between 29.4 and 46.1oC when vegetable fat is used for good stand up
quality and mouth-feel.  A melting point higher than the recommended
range could lead to a waxy mouth-feel upon consumption. Fat provides
shortening effect to caramel and reduces the stickiness in product. Fat also
affects the adhesion properties of caramel. Lipid may also affect the shelf
life stability of a caramel with the potential for rancidity or fat expression.
Fat expression is a defect that occurs when there is poor emulsification and
results in a greasy caramel surface.

SALT:
Salt is added to caramel to enhance the flavour. It also acts
as humectant and is necessary to prevent the product from being too bland.
An optimum mixture of carbohydrates, protein and fats in caramel product
largely dictates the rheological, thermal and structural properties, and,
therefore, affects the operation and functional properties. Interaction of
three basic ingredients namely carbohydrates, proteins and fats along with
water and other minor additives during shearing, mixing and heating make
an interesting combination in product formulation.

WATER:
The water helps early in the cooking process by causing the mixture
to heat evenly without burning. Most of it boils off. As the water
evaporates, the boiling point of the mixture increases. So, you can
determine the ratio of water to sugar by measuring the temperature while
it's boiling. Once enough water has boiled off to reach the temperature
specified in the recipe, then you know that the ratio of water to sugar is
right. Too much water and the caramel will be too soft. If you add extra
water, it will take longer to reach the target temperature, but you'll still
have the same amount in the end as long as you get it to the right
temperature.

STRUCTURE OF TOFFEE:
Toffee is an emulsion of fat in complex aqueous system. It is a
mixture of sugars, water and protein which is resistant to crystallization.
Toffees have number of textural characteristics:
 Hardness is a function of moisture content.

 Chewiness and toughness on eating are related to molecular weight

of the carbohydrates

 Body is a function of quantity and state of the milk protein and it is

affected by quantity ,degree of emulsification and hardness of fat

All these characteristics of different ingredients affecting the eating

characteristics of the toffee and by varying ratio of the ingredients and
alternative ingredients use leads to give the desired texture of the toffee.

FORMULATION:

• Depends on the requirements of the toffee.

• May be for wrapping as a sweet, for depositing into chocolate shells or
layering onto 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.

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

Shaping of the finished toffee

Cooling of the toffee

Packaging and storage

PROCESSING
Toffees can be made using equipment ranging from an ordinary
saucepan to a large continuous plant. The processes carried out are
fundamentally similar.
a. Dissolving
Solid sugars are first dissolved in water or a mixture of water and
glucose syrup.
b. Emulsifying
The fat and skim milk solids are added into the dissolved sugar or
glucose syrup which makes the emulsion.

COOKING:
The emulsion is then cooked to achieve the final water content. It is
controlled by measuring the boiling point of 118-132°C for regular toffee
and 146-154°C for hard toffee. If the cooking is done in a saucepan or
steam pan, the toffee can then be passed to the next stage. If the toffee has
been cooked in a high technology cooker such as a wiped film or a scraped
surface heat exchanger the moisture is evaporated so rapidly that
caramelization has no time to occur. In such systems either a pressurized
pre-heater or a steam-heated post-cooking holding vessel must be
provided. The residence time in these vessels is then adjusted to give the
desired colour and flavour, and various continuous cookers have been
produced with the specific aim of matching the pan boiled product. It is
possible to have a system where the pre-boil emulsion is made on a batch
basis but which is cooked on a continuous basis once made.
Converting a long-established product from a batch to a continuous
process can create a lot of problems. The product made on the continuous
plant often has a different texture and taste to the original product, other
relate to rheological changes that occur during the cooking process.

SHAPING OF TOFFEE:
The finished toffee has to be shaped in some way. Toffee is normally
run into trays, cut into slabs or used as a component of other
confectionery. There are three processes used for shaping toffees for
individual twist wrapping. The processes are the slab process, cut and
wrap processing as well as depositing.

i. Slab Process
This is a very old-fashioned way of shaping toffee. The toffee is
poured, usually manually, onto water-cooled slabs. In order to facilitate
manipulation of the toffee the slabs are coated with a release agent.
Traditionally, this was a mineral oil although its use has been banned and
long-life vegetable fats are now used. Because toffee is a poor conductor
of heat it must be turned over on the slab to bring the cooler outer part into
the middle and to bring the hotter middle onto the slab. If the toffee was
just left on the slab to cool without turning the outside would be hard
before the middle had cooled down. After sufficient cooling the toffee is
cut into sheets before being cut into individual pieces.

ii. Cut and Wrap Process

In this process the toffee is cooled, usually by pouring it onto a
cooled metal drum or band although cooling could be carried out on a slab
if required. The temperature of cooling must not go low enough to cause
condensation, which will occur if the product is below the dew point. The
cooled product is then fed to rollers known as batch rollers that shape the
mass into a cone and then a rope. The rope then passes through further
rollers to reduce the thickness of the rope and then past forming wheels
that produce the desired cross section. The product is cut with a rotating
knife and the pieces are fed onto the wrapping paper and twist wrapped.
Modern machines work at very high speeds. Although it is very quick, one
problem with this type of system is that the individual pieces of toffee are
distorted during wrapping.

iii. Depositing
This is the most modern process of the three. Soft caramels can be
deposited into starch moulds or chocolate shells which are later sealed by
adding a chocolate back. The high technology method is to deposit the
toffee into rubber moulds. The problem of making such a deposit is that
the depositing machinery must be kept sufficiently hot for the toffee to
flow without any further loss of water. Toffee can thicken up if held for
too long at high temperature. In the subsequent cooling stage the problem
is to abstract heat from the product and to do it without cooling it so much
that condensation occurs. The rate at which heat can be removed
from the finished toffee is controlled by the thermal conductivity of the
toffee, which is low. After cooling, the toffees are fed to the wrapping
machine for packing.

Toffee texture
Toffee textures are sometimes modified by the incorporation of air,
which is introduced by mixing in a whipped frappe, and toffees are
frequently combined with other confectionary products. In these
conditions the main attention on the relative humidity of the separate
components as, it may lead to moisture transfer to the sweets leading to
change in the texture and in case of dried nuts and fruits which lead to
prevent moisture being introduced into the toffee and initiating grain.
Reworking toffee products depends on the type of process involved. Solid
rework can be added back either on the slab or into the boiled batch but,
care should be taken that no grain developed on the surface of the rework.
It is safer to dissolve the rework to premix solid and feed it back at the
premix stage. It has been said that a proportion of rework improves toffee
texture and improves flow characteristics in depositing processes.

Packaging and storage

Toffees are mostly packed in individual wraps can be made from
waxed paper, aluminium foil and cellulose film or a combination of these.
In most cases toffees will be wrapped by hand, but for higher production,
semi-automatic wrapping machines are available. For further protection,
the individually-wrapped sweets may be packed in a heat-sealed polythene
bag.
Toffees are mostly stored under the ambient conditions of
temperature and humidity.

FSSAI STANDARDS:
SUGAR CONFECTIONERY whether sold as hard boiled sugar
confectionery or pan goods confectionery or toffee or milk toffee or
modified toffee or lacto-bon-bon or by any other name shall mean a
processed composite food article made from sugar with or without
doctoring agents such as cream of tartar by process of boiling whether
panned or not. It may contain centre filling, or otherwise, which may be in
the form of liquid, semi-solid or solids with or without coating of sugar or
chocolate or both.

It shall also conform to the following standards, namely:-

(i) Ash sulphated - Not more than 2.5 (on salt free basis) per cent
by weight. Provided that in case of sugar boiled confectionery
where spices are used as centre filling, the ash sulphated shall
not be more than 3 per cent by weight.
(ii) Ash insoluble (in dilute Hydrochloric acid) Not more than 0.2
Per cent by weight. Provided that in case of sugar boiled
confectionery where spices are used as centre filling, the ash
insoluble in dilute Hydrochloric acid shall not be more than
0.4 per cent. Where the sugar boiled confectionery is sold
under the name of milk toffee and butter toffee, it shall
conform to the following additional requirements as shown
against each;

(1) Milk toffee-

i. Total protein (N x 6.25) shall not be less than 3 per

cent by weight on dry basis.
ii. Fat content shall not be less than 4 per cent by
weight on dry basis.

CREAM including sterilised cream means the product of cow or

buffalo milk or a combination thereof. It shall be free from starch and
other ingredients foreign to milk. It may be of following three categories,
namely:-
 1. Low fat cream--containing milk fat not less than 25.0 percent by
weight.

2. Medium fat cream--containing milk fat not less than 40.0 percent
by weight.

3. High fat cream--containing milk fat not less than 60.0 percent by
weight. Note:- Cream sold without any indication about milk fat content
shall be treated as high fat cream.

FAT

 Not less than 4 g per 100 Calories (0.93 gram per 100
available kilojoules)
 Not more than 6 gram per 100 calories (1.4 gram per 100
available kilojoules)

SALT

Edible common salt is crystalline solid, white, pale pink or

light grey in colour with the maximum moisture content of 6%. As
per the FSSR Regulations, the sodium chloride content and matter
soluble in water shall comply with the standards as mentioned in the
table below. The insoluble content in common salt must not exceed
1.0 percent by weight on a dry basis

If an anticaking is added to the salt it shall not exceed 2.2

percent and the sodium chloride content must not be less than 97.0
percent by weight.
COST OF MANUFACTURE:

UNIT
WEIGHT TOTAL
S.NO INGREDIENTS COST(1000g/Rs
TAKEN(g) COST(Rs)
)

1 SUGAR 200g 50 10

2 BROWN SUGAR 100g 100 10

3 CREAM 300ml 200 60

4 BUTTER 125g 470 58.75

VANILLA
5 5ml 200/50ml 20
EXTRACT

6 MISCELLANEOUS - 2 2

TOTAL COST OF MANUFACTURE 160.75

REFERENCE:

https://www.bbcgoodfood.com/recipes/chewy-toffees

https://old.fssai.gov.in/Portals/0/Final_Regulations_2010.pdf

http://ecoursesonline.iasri.res.in/mod/resource/view.php?id=5884
http://epgp.inflibnet.ac.in/epgpdata/uploads/epgp_content/food_technolog
y/bakery_and_confectionery_technology/28.technology_of_caramel,_toffe
e__and_fudge/et/2824_et_m28.pdf
http://epgp.inflibnet.ac.in/epgpdata/uploads/epgp_content/S000015FT/P00
0072/M002824/LM/1500271669Pp09Mdl28.pdf