Know Your Fats

(Oils & fats training)

Date : 22nd April, 2014

Venue : My Academy Innovation Room
IOI Loders Croklaan Asia,
Pasir Gudang, Malaysia
CONTENT

(Page)
i. List of Figures 4
ii. List of Tables and Charts 5

1. Chapter 1: Oils and Fats Basics 6

1.1 Structure 7
1.2 Composition 9
1.3 Oxidation and Shelf life 12
1.4 Polymorphism and Eutectics 15

2. Chapter 2: Oils and Fats Parameters 16

2.1 Peroxide Value 16
2.2 Free Fatty acid 16
2.3 Iodine Value 17
2.4 Saponification Value 17
2.5 Slip Melting Point 18
2.6 Solid Fat Content 18

3. Chapter 3: IOI Loders Croklaan Products 21

3.1 Product overview 21
3.2 Application Support and Innovation 24
3.3 Creative Studio 24

4. Chapter 4: Product Applications 26

4.1 Coating Fats 26
4.1.1 Cocoa butter and its properties 27
4.1.2 Cocoa Butter Equivalent 29
4.1.3 Cocoa Butter Substitute 41
4.1.4 Cocoa Butter Replacer 44
4.1.5 Coating Recipes 47

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CONTENT

(Page)
4.2 Filling Fats 50
4.2.1 Classification 50
4.2.2 Shell molded fillings 50
4.2.3 Extruded fillings 51
4.2.4 Cool Melting fillings 52
4.2.5 Aerated Fillings 52
4.2.6 Biscuit and Wafer Fillings 53

4.3 Bakery Fats 54

4.3.1 Shortening 54
4.3.2 Milk Fat Replacer 55
4.3.3 Margarine and Hardstocks 56

4.4 Dairy Fats 57

4.4.1 Non-Dairy Creamer 57
4.4.2 Ice cream 58
4.4.3 Whipping Cream 58
4.4.4 Cheese 59
4.4.5 Filled Milk 60

Reference 61

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CONTENT

I. List of Figures (page)

1.1 Chemical Structure of oils and fats 6

1.2 Structure of Triacylglycerides 7
1.3 Structure of Diacylglycerides 10
1.4 Structure of 1,2-Monoacylglcyerides 10
1.5.1 & 1.5.2 Structure of Fatty acids 11
1.6 Cis and Trans isomers of unsaturated fats 9
3.1 Creative Studio Asia Facility 25
4.1 IOI Loders Croklaan Asia Product Applications 26
4.2 Symmetrical Triglycerides found in cocoa butter 28
4.3 Cross cutting view of Palm Fruit 30
4.4 Ripened Shea Fruits and Shea nuts gathering 32
4.5 Illipe tree, Illipe fruits, Illipe nuts and Illipe Kernels 33
4.6 Sal Kernels and Kokum Kernels 34
4.7 CBE Legislation in traditional chocolate around the world 38
4.8 Enzymatic CBE reaction 39

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CONTENT

ii. List of Tables and Charts (page)

1.1 Melting points of different saturated Fatty acids 8

1.2 Eutectics: coating fats with Cocoa Butter 14
2.1 NMR melting curve of the Cocoa Butter by SFC 19
4.1 Relative Crystallization time of Cocoa Butters 4.1
4.2 Typical triglyceride distribution of Palm oil 30
4.3 Typical triglyceride composition of Kokum oil 34
4.4 Typical triglyceride composition of Mango Kernel Oil & its Stearin 35
4.5 Chocolate composition to meet US Standards 37
4.6 SFC of Coberine™ Range 40
4.7 SFC of blends of CBE and CBI & Cocoa Butter 40
4.8 SFC of CBS’s from IOI Loders Croklaan Asia 42
4.9 SFC of CBR’s from IOI Loders Croklaan Asia 45
4.10 SFC of non-hydrogenated Couva Range 46
4.11 Chocolate & Coating recipes using Coberine™ (CBE) 47
4.12 Compound Coating recipes using CLSP™ (CBS) 48
4.13 Compound Coating recipes using Couva™ (CBR) 48

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 Chapter 1: Oils and Fats Basics

1. Oils & Fats Basics

Oils and fats belong to the common category of so-called Lipid’s, which forms one of the im-
portant constituents of food. These are one of the three main energy contributing nutrients in
food with carbohydrate and protein being the other two nutrients. Compared to carbohydrates
and proteins, which carry each 4 Kcal energy per gram, fat contributes 9 Kcal energy per
gram. Hence their intake has been of great interest for nutritionists. Fat also acts as carrier
for the fat soluble vitamins like Vitamin A, D, E and K in the human diet.

A Lipid can be named an oil or fat depending on its physical characteristics or its appearance
in the country of origin. As a rule, oils are liquid at room temperature and fats are solid at
room temperature. Though both oils and fats carry similar chemical structure, certain small
differences can largely influence their texture, functionality, shelf life and nutritional values.

1.1 Structure of Oils & Fats

-OOCR represents fatty acids

where R1, R2 and R3 are Alkyl groups

(Carbon & Hydrogen atoms)

Fig 1.1: Chemical Structure of Oils and Fats

Oils / fats are chemically termed as Tri-acylglycerides (TAG) which is basically the combina-
tion of three fatty acids on a glycerol backbone. TAG’s are the predominant components pre-
sent in animal as well as vegetable oils and fats. They are hydrophobic meaning not able to
dissolve in water.

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 Chapter 1: Oils and Fats Basics

Fig 1.2: Structure of Triacylglcyeride

The type of fatty acids present in this chain as well as the position of the fatty acids in the
glycerol backbone can largely influence the texture, functionality, shelf life and nutrition. In
case only one or two fatty acids are present in the glcyerol, they are termed as monoacyl-
glycerides (MAG) or monoglycerides and diacylglcerides (DAG) or diglycerides respectively.

DAG have one –OH part left out from esterification. The –OH part helps in partial miscibility
with water. Hence diglycerides are commonly used in emulsifier system where water in Oil
(W/O) emulsions are preferred like margarine and mayonnaise application. The –OH part can
be located in any of the three positions of the glycerol backbone. The two fatty acids will be
lipophilic (fat loving) while the –OH part being hydrophilic (water loving).

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 Chapter 1: Oils and Fats Basics

Fig 1.3: Structure of Diacylglcyeride

MAG are glycerides containing only one fatty acid attached to glycerol backbone with two –OH
parts left out without esterification. They have better miscibility with water compared to di-
glycerides because of their double –OH part compared to single –OH part of diglycerides.

They are often considered to provide better emulsification properties than DAG and used in
emulsifier system where Oil in Water (O/W) emulsions are preferred like milk, cake etc. De-
pending on position of the ester bond in the glycerol it can be named as 1-Monoacylglceride
(fatty acid on 1st position) or 2-Monoacylglyceride (fatty acid on 2nd Position).

1 - Monoacylglycerol 2 - Monoacylglycerol

Fig 1.4: Structures of Monoacylglcyerides

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 Chapter 1: Oils and Fats Basics
1.2 Fatty acids:
A fatty acid is a carboxylic acid with a long aliphatic chain. They are the main structural com-
ponent in the oils and fats of both vegetable and animal origin. Most of the naturally occurring
fatty acids have a chain length of an even number of carbon atoms ranging from 4 to 28.
They could be categorized depending on the chain length, as given below;
 Short chain (4 – 6 numbers of carbons)
 Medium Chain (8 – 14 numbers of carbons) and
 Long Chain (16 and higher numbers of carbons)

Lauric Acid (C12)

Palmitic Acid(C16)

Fig 1.5: Structures of Fatty acids

They can also broadly be classified into three major groups depending on the number of dou-
ble bonds present in the fatty acid. They are:
 Saturated fatty acid (SAFA), indicated as C12:0, C16:0
 Mono unsaturated Fatty acid (MUFA), indicated as C18:1
 Poly unsaturated Fatty acid (PUFA), indicated as C18:2, C18:3

Fig 1.5: Structures of C18:1 Oleic acid and C18:2 Linoleic acid
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 Chapter 1: Oils and Fats Basics

1.2.1 Saturated Fatty Acids (SAFA):

Saturated Fatty acids generally have high melting points and they don’t contain any double
bonds. The length of the fatty acid determines the melting point of it that higher the length
then higher is their melting point (see table 1.1).

Saturated fatty acids are hard to breakdown and they have very good stability towards oxida-
tion compared to unsaturated fatty acids. They provide the required texture and structure for
the final products and are industrially most preferred fat because of these reasons. They are
predominantly present in tropical oils like Coconut oil, Palm oil and Palm Kernel oil.

Tab 1.1: Melting points of different Saturated Fatty acids

(Source: William Reusch, msu)

1.2.2. Monounsaturated Fatty acids:

Monounsaturated Fatty acids contain one (‘mono’ means single) double bond and they have
lower melting point compared to a saturated fatty acid having the same carbon number. Mono
unsaturated fatty acids are liquid at room temperature and semi-solid when refrigerated. The
common Monounsaturated fatty acid is Oleic acid which is represented as C18:1, it is com-
monly found in Olive oil, Palm olein and Canola oil. It is termed as omega-9 fatty acid.

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 Chapter 1: Oils and Fats Basics

1.2.3. Polyunsaturated Fatty acids:

Polyunsaturated Fatty acids contain more than one (‘poly’ means many) double bonds and
they are much more liquid than the saturated fats and monounsaturated fats. The omega-3
and omega-6 fatty acids which are essential fatty acids for normal growth and metabolism
belong to the polyunsaturated fatty acids group.

They are highly prone to oxidative rancidity compared to other fatty acids and industrially sel-
dom their use is recommended because of the short shelf life. They are abundant found in
Fish oils, Sunflower oil and Soyabean oil.

1.2.4. Trans Fatty acids:

Most of the naturally occurring unsaturated fatty acids from vegetable origin are the so-called
cis isomers, which mean the hydrogen atom across the double bonds are in same direction.
During the refining process, there might be a slight isomerization happening with the unsatu-
rated fatty acids because of too high a temperature. This results in trans isomers formation
which have the hydrogen atoms across the double bonds; these are categorized as transfats.

Trans-fats are industrially produced often because of the partial hydrogenation process. The
isomerization process helps in increasing the melting point of the fatty acid and provides bet-
ter stability towards oxidation.

Cis - monounsaturated fatty acid chain

Trans - monounsaturated fatty acid chain

Fig 1.6: Cis and Trans isomers of unsaturated fatty acids

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 Chapter 1: Oils and Fats Basics

1.3. Stability and Shelf Life:

In adverse conditions, oils and fats get broken down to cause rancidity. Rancidity is a term
widely used for the description of off-flavors arising from degradation of fat and detectable
mainly in the later stages of chemical decomposition of oils and fats. Rancidity can be of three
types namely,
 Hydrolytic rancidity
 Oxidative rancidity
 Microbial rancidity

1.3.1. Hydrolytic rancidity:

Hydrolysis of oils and fats occur when fatty acid chains get split away from the glycerol back
bone in the presence of water. The chemical term is ester hydrolysis and this results in the
formation of ‘free’ fatty acids. Usually this hydrolysis process doesn’t give much sensory de-
fects at low levels since most of the free fatty acids are odorless and have little off-taste.
However short chain or medium chain fatty acids can result in strong flavour and odour. The
soapy taste problem found in coatings based on Cocoa butter Substitutes is because of the
hydrolytic rancidity caused by the lauric (C12:0) free fatty acids. Control in moisture content
and use of water scavengers like lecithin helps prolong the shelf life caused by this spoilage.

1.3.2. Oxidative rancidity:

Oxidative rancidity is a process of breakdown of fatty acids in the presence of air or oxygen
resulting in an off-flavour and unpleasant rancid smells. Through the free radical process, the
double bonds of unsaturated fatty acids can undergo cleavage, releasing volatile aldehydes
and ketones.

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 Chapter 1: Oils and Fats Basics

This is the reason for the longer shelf life received by saturated fats (which don’t have any
double bonds) compared to the unsaturated fats. The oxidation process consists of three
stages namely,
 Initiation
 Propagation
 Termination

Use of antioxidants like Tocopherols (natural) and BHA (synthetic) will help prolong the shelf
life caused by this spoilage. Addition of chelating agents like citric acid will help to inactivate
the metal ions involved in free radical formation which initiate the oxidation process.

1.3.3. Microbial rancidity:

Microbial rancidity is caused by microorganisms like bacteria which produce enzymes like li-
pases to break down the fat. Good hygienic conditions and proper handling of ingredients can
help delay this process. This spoilage can be prevented by sterilization processes of raw ma-
terials.

1.4. Polymorphism:

Polymorphism is the term used to describe the different crystal forms or arrangement of tri-
glycerides (fats). ‘Poly’ means many and ‘morph’ means forms. The fat molecules gets packed
in different ways to form crystals which can be named as α (alpha), β’ (beta prime) and β
(beta) with certain sub forms in between them. The sub forms are generally termed as β1’, β2’
etc. The melting point of each crystal form ranges from low into high for the same triglycer-
ide. β crystal form is considered to be the most stable form of crystals.

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 Chapter 1: Oils and Fats Basics

All fats can crystallize in two or more than two crystal forms, meaning they all are polymor-
phic though people mention the non-tempering fats as non-polymorphic fats. In non-
tempering coating fats like CBS and CBR, there will be one unstable (α) form and one stable
(β’) form, however crystallization will happen spontaneously in the stable form.

In chocolate coating fats like cocoa butter and CBE, there will be a third (β) form which is
most stable making it important to do a tempering process that will help to develop the right
crystal forms before final crystallization. Chocolate tempering is a process of programmed
temperature variation to achieve the right crystal preceding the chocolate application.

1.5 Eutectics

As explained earlier all the fats used in different food application contain blends of different
types of triglycerides. Each of these triglycerides interacts with each other in different ways
called phase behavior. This is the reason why most of the fats have wide range of melting
temperature and they are not 100% solid at usual storing conditions. When fats with similar
melting profile but with totally different triglycerides composition are mixed the resulting
blend shows additional softening at certain ratio’s and temperature than could be expected
from the two fats. This phenomenon is called Eutectics.

Cocoa Butter Equivalent Cocoa Butter Replacer Cocoa Butter Substitute

Table 1.2: Euctectics—Coating fats with Cocoa Butter

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 Chapter 1: Oils and Fats Basics

Eutectic effects are commonly seen particularly while blending two fats having different tri-
glycerides composition with one having long chain fatty acids while the other having mainly
short chain fatty acids. The typical example being blending Cocoa butter with Cocoa Butter
Substitute (CBS) which mainly contains lauric fatty acid compared to Palmitic and Stearic fat-
ty acids of cocoa butter. That’s the main reason why CBS is not compatible with Cocoa butter
however fats like Cocoa Butter Replacer (CBR) which is also composed mainly of long chain
fatty acid has better compatibility with Cocoa butter.

Cocoa Butter Equivalent is 100% compatible with Cocoa butter because they have a compara-
ble chemical structure as Cocoa butter. Cocoa Butter Equivalents are high end confectionary
specialty fats which are made by blending special fractions of Palm, Shea, Illipe, Sal, Kokum
and Mango Kernel fats that are similar in structure as that of cocoa butter.

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 Chapter 2: Oils and Fats Parameters

Understanding the various parameters mentioned in a fat specification is important not only in
choosing the right fat but also it helps in knowing the functionality of the fat in each of the
end application. Certain parameters are very critical in safeguarding special requirements
which prevent difficulties in processing as well as shelf life requirements.

2.1 Peroxide Value (PV)

Peroxide values give initial indication on the deterioration of the oils & fats and it gives a
measure of the extent to which the oil has undergone primary oxidation. Peroxides are the
intermediates formed by the oxidation of oils in the presence of oxygen that leads to rancidi-
ty. Rancidity is a term widely used for the description of off-flavors arising from auto-
oxidation and detectable mainly at a later stage of oxidation.

The general specification for all the oils and fats from IOI Loders Croklaan is 1.0 meq.O 2/Kg
max on ex-factory basis. However, incidentally fats with higher PV than this limit could still be
acceptable for consumption. A peroxide value shows the concentration of peroxides in the oils
and fats that indicates the rate of oxidation it has undergone so far. The test employs a titra-
tion method and is rather easy to perform.

2.2 Free Fatty Acid (FFA)

Free Fatty acids are formed because of the hydrolytic rancidity of triacylglycerides. Hydrolysis
is a process of splitting of fatty acid chains away from the glycerol backbone in the triacyl-
glycerides (TAG) in the presence of water. These free fatty acids are more prone compared to
normal TAG’s to undergo further autoxidation.

Also the FFA of shorter chain fatty acids can be easily detected by sensory and can drastically
affect the taste profile of the oil. For example, free fatty acid of Lauric fats like palm kernel oil
and coconut oil can result in soapy taste of the final product already at low levels. This issue
is particularly of concern with confectionary fats like Cocoa Butter Substitutes which are based
out of lauric fats. 16
 Chapter 2: Oils and Fats Parameters

Long chain fatty acids can also be detected by sensory but needs to be in higher concentra-
tion compared to the short chain fatty acids. The general specification of all the oils and fats
from IOI Loders Croklaan for Free Fatty Acid is 0.10% (w/w) max on ex-factory basis.

2.3 Iodine Value (IV)

Iodine Value indicates the level of saturation present in the given oils and fats. Oils having
high concentration of unsaturated fatty acid in their TAG will have higher Iodine Value. Iodine
value will be lesser for oils and fats having high concentration of saturated fats like Coconut
oil and Palm kernel oil. Full hydrogenation process of oils and fats will reduce the Iodine value
since it involves conversion of unsaturated fats to saturated fats.

The term Iodine Value is used because of the Iodobromine which is used as the reagent in
this assay. As Iodine value varies from product to product and the functionality of the fat
can’t be fully decided using this variable, it is not considered as a critical parameter. The pro-
portion of saturated versus unsaturated fats can be checked on the nutritional content men-
tioned in the specification sheet of IOI Loders Croklaan. For certain oils where higher IV is
preferred to avoid clouding found in bottled oil, another critical parameter like cloud point is
provided separately.

2.4 Saponification Value (SV)

Saponification value is the measurement of the average molecular weight or in other words
the chain length of all the fatty acids present in given oil and fat. It is represented by the
number of milligram of alkali like Potassium hydroxide or Sodium hydroxide required to sa-
ponify 1g of fat under the condition specified. It is used for comparing the average fatty acid
chain length as most of the fats are mixture of different triacylglycerides (3 different fatty ac-
ids in glycerol backbone). Since this is not a critical parameter that could affect the functional-
ity of the end application, this is not mentioned in the specification sheets of IOI Loders
Croklaan. 17
 Chapter 2: Oils and Fats Parameters

2.5 Slip Melting Point (SMP)

Slip Melting Point or “Slip Point” is one conventional definition of the melting point of a waxy
solid, like Fats. This is a popular method for fats and waxes, because they tend to be mixtures
of compounds with a range of molecular masses, all differing in well-defined melting points.
This parameter is generally measured using degree Celsius (°C).

Slip melting point can be defined as the temperature at which the fat is close to complete
melting. General perception with this parameter is that lower or higher melting point means
the fat will be softer or harder in texture respectively but the actual fact is that they are not
always correct.

With respect to functionality in the application, it has limited value hence in IOI Loders
Croklaan we commonly don’t mentioned this parameter in our specification as it is not a criti-
cal factor to compare. Other parameters like Solid Fat Content which could provide more de-
tailed information on the functionality and behavior of the fat are generally provided instead
in the specification sheets.

2.6 Solid Fat Content (SFC)

Solid Fat Content measures the percentage of solid fat, or in other words the hardness of the
oils and fats at various temperatures. All the oils and fats are blends of different triacylglycer-
ides with each having a different melting point and they are not 100% solid at most of the
application temperatures. As the temperature increases the percentage of solid will decrease
as some of the triacylglycerides melt over that temperature range.

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 Chapter 2: Oils and Fats Parameters

In earlier days, the hardness of fats were determined indirectly by dilatometry. This method
is based on the fat contraction once it starts to solidify. This is indicated in mm 3/25gm as Sol-
id Fat Index (SFI). But nowadays, SFI for oils and fats is measured using the low resolution
Nuclear Magnetic Resonance (NMR) to get more accurate information as this parameter is
very critical to know the functionality of the fat in a given application. A graph can be plotted
using the SFC against different temperatures which is termed as the melting profile of fat and
at times, it is also called as NMR curve.

The NMR curve can provide very clear detailed information about the texture, physical proper-
ties as well as sensory characteristics of the oils and fats. It is the most important and critical
parameter to compare and get to know the actual functionality of the fat in each of the appli-
cations. Most of the specification sheets from IOI Loders Croklaan will contain the information
about the Solid Fat Content so that the customer could understand the functionality of the fat
in their product application.

Among the confectionary fats, SFC for tempering fats like Cocoa Butter and CBEs are done by
a long lasting stabilization the fat at temperature of 20°C and 26°C (stabilized IUPAC Method
2.150(b)) before the evaluation. For the non-tempering fats like Cocoa butter Replacers, the
SFC is evaluated on a much shorter time os stabilization(unstabilized IUPAC Method 2.150
(a)).

Table 2.1 NMR melting curve of Cocoa Butter by Solid Fat Content (SFC) 19
 Chapter 2: Oils and Fats Parameters

The following characteristics of the oils and fats can be understood using their NMR melting
curve,
Hardness:
Fat having high NMR values at room temperature are considered to have a hard texture.

Heat Resistance:
The level of SFC from 20–27°C gives an indication of the heat resistance of the fat. There are
certain debates on this temperature range as certain tropical countries can have very high
outside temperatures and the range of temperature to define heat resistance can vary. How-
ever, it is reality that very rarely confectionary products are eaten at those high tempera-
tures.

Melt Down:
Depending on the specific slope between 25°C and 30°C, a fat’s melting down characteristics
can be understood. A sharp slope indicates a rapid melting of the fat and a very fast release
of the flavor. A shallow slope indicates about an opposite tendency. If the slope is very sharp
and almost when the SFC gets close to zero at these temperature then it tends to provide a
cool melting sensation while eating the product made with this fat.

Waxiness:
High level of SFC present at temperature above the body temperature (<37°C) tends to give
a waxy taste as there are still some non-melted fat remain in the product. If the Solid fat con-
tent value at body temperature falls to zero then the fat shows a clean melting taste.

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 Chapter 3: IOI Loders Croklaan Products

IOI Loders Croklaan has more than 120 years of experience in the oils and fats business.
They are pioneer in specialty fats and oils supplied to global food industry including the choc-
olate confectionary, bakery, Margarine, Dairy and industrial frying.

3.1 Product overview

The following brands of IOI Loders Croklaan are familiar to most of the food manufacturers
around the world, offering innovative oils and fats that can be used to create products in line
with the very latest market trends.

Coberine™ Range - Cocoa Butter Equivalent (CBE)

 Comparable processing and eating properties as cocoa butters
 Fresh and clean melting
 100% compatible with cocoa butter (both rich in symmetrical triglycerides)
 No change in hardness / melting when mixed with cocoa butter

Couva™ Range - Cocoa Butter Replacer (CBR)

 Acceptable texture and meltdown
 Compatible with cocoa butters upto 20% of the fat phase
 Easy to process as no tempering required
 Cost-effective
 Trans free products available

CLSP™ Range - Cocoa Butter Substitute (CBS)

 Provides quick meltdown and good snap to coatings
 Limited compatibility with cocoa butter up to 5% of the fat phase
 Easy to process as no tempering required
 Excellent de-moulding properties

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 Chapter 3: IOI Loders Croklaan Products

Creamelt™ Range - Premium Filling Fat

 Fast, cool and ‘clean’ melting properties
 Maximizes flavor release
 Contains symmetrical triglycerides which requires pre-crystallization during processing
 Non-lauric and non-hydrogenated, free of trans fatty acids

Biscuitine™ Range - Non-Lauric conventional filling fat

 Non-lauric by nature
 Fine texture, full, creamy meltdown & corresponding flavor release
 Does not require tempering or pre-crystallization
 Available in both hydrogenated and non-hydrogenated version

CLSP™ Range – Lauric Filling Fat

 Non-tempering, easy processing
 Cool and clean melting properties

Durkex™ Range - high Stability oil and Spread fat

 Can be used as a frying medium, release agent, anti-dust oil, glazing agent, carrier. For
spreads, liquid fillings and spraying oil.
 Resistant towards oxidation & polymerization acheiving longer ‘frying cycle’

Revel™ Range – Hardstock and Structuring fat

 Acts as a crystallization enhancer, stabilizer and structuring agent
 Extensively used in bakery, dry mixes, culinary products, soup and sauces
 Available in flake form

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 Chapter 3: IOI Loders Croklaan Products

Carabuta™ - Milk Fat Replacer

 Vegetable fat containing essential flavor precursors of milk fat
 Used to replace or extend dairy butter in bakery and confectionary products like toffees,
caramels, desserts, biscuits and baked goods

BOS – Butter Oil Substitute

 Fractionated, non-hydrogenated vegetable fats of non-lauric origin with the addition of
butter flavor and colour
 Used to replace or supplement dairy butter in sauces, soups, desserts and coffee roast-
ing.

Shortfat Range – Vegetable Shortenings

 Multipurpose fats with excellent plasticity that provides extensive application opportuni-
ties in bread, biscuits, cakes, pastries and filling application
 They are non-lauric and non-hydrogenated.

Marfat Range– Margarine

 Marfat’s are based on fractionated, hydrogenated vegetable fats with added flavor,
emulsifiers and salt.
 Maximum moisture content of 16%

Betapol® - Human Milk Fat replacer

 Mimics the human milk fat (Palmitic acid in the Sn2 position)
 Ideal fat to use in the infant formulation
 Health benefits include increased absorption of calcium and fat from diet, improved bone
mineral density and reduction in hard stools.

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 Chapter 3: IOI Loders Croklaan Products

3.2 Application Support

Being pioneer in the specialty fat business, the global Research and Development team in IOI
Loders Croklaan work together with their customers in developing the right fat with function-
ality that satisfies their different needs.

Specialized R&D and Application experts are working together with the customer in develop-
ing new fats as per their requirement up to customizing the final recipe of the customer’s
product. As a problem-solving, product enhancement and creative innovation partner, the ap-
plication team can add long-term value to the customer’s business in many ways.

3.3 Creative Studio

The Creative Studio is the application centre of IOI Loders Croklaan with an unique setup to
combine innovation, creativity and expertise making it a logic partner for new product devel-
opment for customer projects. The Creative Studio Asia together with the other two facilities
located in Europe and America turns the IOI Loders Croklaan motto of “Let’s Create Together”
into an exciting hands-on experience.

The Creative Studio is a place where the food manufacturer can dream up new products and
learn recipes directly from world-class chocolatiers and application experts. The Creative stu-
dio provides the environment and focus on creativity, in which food manufacturers can work
with IOI Loders Croklaan’s dedicated specialists to transform their ideas into a commercially
viable reality.

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 Chapter 3: IOI Loders Croklaan Products

Fig 3.1: Creative Studio Asia Facility

The Creative Studio Asia consists of training rooms, a laboratory area and processing facility
where the manufacturers can put their ideas into practice. The facility contains A to Z pilot
scale equipment necessary for producing chocolate confectionary products, dedicated Bakery
and dairy equipment are available for producing a wide variety of innovative new products.

Other than the full fledge pilot scale facility for creating new products, the facility also con-
tains special analytical equipment to check the texture and consistency of the final products
that were created new in the facility.

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 Chapter 4: Product Application

Starting from premium coating with cool melting filling to butter cookies and aerated cake
cream, the fats from IOI Loders Croklaan can provide a very wide range of application bene-
fits to the food manufacturers. The majority of the fats produced here finds application in
Chocolate Confectionary, Bakery, Icecream, Analog Cheese, Whipping Cream, Infant Formula,
Non-Dairy Creamers, Culinary products and Industrial frying etc.

Fig 4.1: Loders Croklaan Asia Product Application

4.1 Confectionary Coating Fats

Chocolate confectionary in general term is a sweetened and fattened cocoa product produced
from the cocoa beans. Cocoa bean cultivation and use has documentation back to around
1100BC, mainly consumed in South America at the Aztecs as the intense bitter tasting drink
(xocolãtl meaning “bitter water”).

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 Chapter 4: Product Application: Coating Fats

It was only in the 19th century that the Europeans start producing the solid chocolate what we
see now in the market containing extra fat, sugar and milk powder. Generally around one-
third of the chocolate is the fat which comes from the cocoa bean called as Cocoa butter.

4.1.1 Cocoa Butter and its properties

Cocoa Butter is the edible vegetable fat found in the cocoa beans. Cocoa Mass or Cocoa Liq-
uor is obtained from refining fermented, roasted, de-shelled cocoa bean and it contains
around 50 – 56% of Cocoa butter.

The cocoa mass is pot pressed to separate the solid and liquid parts, i.e. cocoa cake and co-
coa butter in approximately the same relative proportions. With pot presses it is not possible
to separate the cocoa butter totally from the other ingredients. The Pressed Cocoa cake is
then grinded to get cocoa powder which comes with a residual fat content of 10 – 12% or
20—22% which is cocoa butter.

The cocoa butter content present in both the cocoa mass (~54%) and cocoa powder (~11%)
is critical particularly during blending with other specialty fats that have limited compatibility
with the cocoa butter.

Cocoa Butter is also called as “theobroma oil” and it is pale yellow coloured solid fat at room
temperature. Cocoa Butter mainly consists of symmetrical triacylglycerides with Palmitic,
Stearic and Oleic fatty acids being the majority of the components. Cocoa butter is therefore
polymorphic in nature and the chocolate made with this fat needs special tempering process
before moulding to get the right gloss, contraction and shelf life.

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 Chapter 4: Product Application: Coating Fats

Fig 4.2: Symmetrical Triglycerides found in Cocoa butter

The melting and crystallization are the important properties of chocolate which are influenced
by the Cocoa butter. Cocoa beans are from a tropical crop mainly grown over the belt of the
equator starting from Brazil up to Ghana, Ivory Coast until Malaysia and Indonesia. Cocoa
butter from different regions shows considerable difference in the above mentioned properties
depending on the local climate.

Table 4.1: Relative Crystallization time of Cocoa Butters

The Indonesian and Malaysia cocoa butters are harder and have a quicker crystallization time
compared to cocoa butter from other regions. The main difference is because of the difference
in the blends of triglycerides.

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4.1.2 Cocoa Butter Equivalent

Cocoa butter equivalents (CBEs) are vegetable fat mixtures with physical and chemical prop-
erties similar to cocoa butter that can be used to replace this expensive ingredient in choco-
late making. Therefore, CBEs are compatible with cocoa butter in any ratio. CBE triglycerides
mimic cocoa butter, which is made up mainly of symmetrical triglycerides and CBE have the
same polymorphism as cocoa butter. The triglyceride POS, SOS, POP make up more than
75% of the total amount of triglycerides found in cocoa butter and CBEs.

CBEs are sourced from vegetable fats which contain similar triglycerides that are found in co-
coa butter. As no single fat could have similar proportion of triglycerides found in cocoa but-
ter, several vegetable fats or fractions of the fats are mixed in order to resemble cocoa butter
as closely as possible. They are
 Palm oil (Elaeis guineensis and Elaeis olifera)
 Shea (Butyrospermum parkii)
 Illipe (Shorea stenoptera)
 Sal (Shorea robusta)
 Kokum gurgi (Garcinia indica)
 Mango kernel (Mangifera indica).

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 Chapter 4: Product Application: Coating Fats

Palm oil

Palm oil is a commercial available vegetable oil that is traded globally and be abundantly sup-
plied with fruit of the palm tree. About 75% of the palm oil comes from Asia, mainly from Ma-
laysia and Indonesia. The fruit of the palm tree consists of two types of oils, which are palm
oil derived from the outer part of fruit called mesocarp and palm kernel oil derived from the
hard kernel (Figure 4.3). Though both these oils come from the same fruit, they have totally
different profile of fatty acids present in each of them. Palm Kernel Oil is rich in lauric fatty
acid and its profile could be comparable to that of Coconut oil.

Palm kernel

Mesocarp

Fig 4.3: Cross cutting view of Palm Fruit

Palm oil is rich in palmitic fatty acid (~44%) and oleic fatty acid (~39%). Further palm oil
composes a wide range of triglycerides, which can be classified into four groups (Table 4.2).

Glyceride Type Percentage Major Components

Tri-saturated 8.5% PPP

Mono-unsaturated 37.8% POP, PPO

Di-unsaturated 35.1% POO, PPLi

More highly unsaturated 18.6% OOO, PLiO, OOLi

P=palmitic acid; O=oleic acid; Li=linoleic acid

Table 4.2: Typical triglyceride distribution in palm oil

(Berger 2005) 30
 Chapter 4: Product Application: Coating Fats

Palm oil is the source that contributes triglyceride POP with some POSt components to the
CBE. In order to concentrate both triglycerides in the palm oil, the oil is passed through two
stage fractionation process. The di-unsaturated and more highly unsaturated triglycerides are
separated out in a low melting Olein fraction.

The tri-saturated triglycerides are then removed in a high melting stearin fraction and they
are commonly used in the preparation of bakery shortenings which require the non-
hydrogenated status. The symmetrical POP / POSt triglycerides separated in a middle melting
cut, are called as palm mid fractions.

IOI Loders Croklaan was the first to start using special solvent fractionation process to get the
palm mid fraction that is rich in concentrated POP triglycerides. The solvent fractionation
helps in cutting short the fractionation process as well as provides better yield compared to
the dry fractionation process.

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 Chapter 4: Product Application: Coating Fats

Figure 4.4: Ripened Shea fruits & Shea nut gathering.

(Picture Courtesy: moksaorganics, Globalhands, Graphic.gh,UCLA Int. Institute)

Shea butter
Shea butter’s fat composition is remarkably similar to cocoa butter, which is why it is a key
ingredient in CBEs. It is obtained from the fruit of a perennial tree (Butyrospermum parkii),
growth concentrated mainly in West Africa (from Senegal to Ethiopia). The fruit is rather like
a plum and the shea butter is the fat obtained from its kernel. As the fruits can be harvested
only after 15 years of age of the tree, farming is not economically viable.

Besides being an ingredient of CBEs, shea butter is also a popular ingredient in cosmetic and
personal care products, an attribute to its naturally special characteristics for instance superi-
or moisturizing properties, UV absorption ability, anti-aging and wound healing etc. that
aren’t found in other plants. Shea butter is rich in StOSt triglycerides and it is usually fraction-
ated to concentrate the StOSt triglycerides further. Unlike palm oil, it only requires one stage
fractionation to separate higher melting stearin (fraction rich in StOSt) from lower melting
olein (fraction rich in StOO).
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 Chapter 4: Product Application: Coating Fats

Figure 4.5: Illipe tree, Illipe fruits, Illipe nuts & Illipe kernels
(Picture Courtesy: Britanniafoods)

Illipe butter
The Illipe tree grows, sporadically dispersed, in the tropical rain forest of Sarawak and Kali-
mantan on the island of Borneo. It is also called Borneo tallow. The availability of Illipe nuts is
variable from year to year, and depends on the climatic conditions during the maturing peri-
od. In many years, particularly following a large crop, the trees do not flower at the subse-
quent year.

In term of fatty acids and triglycerides composition, Illipe is the closest fat to cocoa butter
among six types of fats. It is high in total triglyceride SOS, as many as does cocoa butter.
Generally, it can be used directly in CBE blending, as a main POSt and StOSt contributor in
the blend. It can in fact be a CBE in its own right, but due to the constraint of availability, re-
sulting in little application in this way.

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 Chapter 4: Product Application: Coating Fats

Figure 4.6: Sal (Left) and Kokum (Right)

(Picture courtesy: Liveodisha.in and clovegarden.com)

Triglyceride Kokum fat

POSt 8.1

StOSt 77.3

StOO 12.1

StLiO 2.5

Table 4.3: Typical triglyceride composition of Kokum fat

(Sridhar 1991)

Sal oil
Sal oil is derived from the seeds of Sal trees which grow in Northern & Eastern India. Due to
dark colour of extracted oil, refining to bleach the oil is required for further usage. The fatty
acid composition of Sal oil has some resemblance to cocoa butter as stearic acid and oleic ac-
id predominates. It also contains some arachidic acid (C20:0), with triglycerides StOA and
AOA present in the oil.

Kokum butter
Kokum is the evergreen tree found in the tropical forest of India. The butter is extracted from
the seed of kokum’s fruit. It is very rich in symmetrical triglycerides. A typical triglyceride
composition is shown in Table 4.3.

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 Chapter 4: Product Application: Coating Fats

Mango Kernel
Mango kernel oil is another CBE’s ingredient to be sourced in India. Stearic fatty acid and ole-
ic fatty acids are predominant; its main symmetrical type of triglyceride is StOSt. Like Shea
butter and Sal butter, the butter needs to be fractionated to concentrate the symmetrical tri-
glycerides in the mango kernel stearin.

Triglycerides Mango Kernel Mango Kernel

Oil Stearine
POP 6.2 2

POSt 12.5 19

StOSt 18.2 58

StOA 0.8 5

PLiP 8.4

StLiP 16.0

POO 7.2

StOO 21.3

StLiO 1.6

OOO 7.7

Others 0.1

Table 4.4: Typical triglyceride composition of Mango Kernel oil and Mango Kernel stearin
(Sridhar 1991 and Arishima 2002)

Legislation
Chocolate legislation varies in different areas of the world. Here we will cover some of them
including the European Union, United States, Latin American countries and CODEX.

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 Chapter 4: Product Application: Coating Fats

European Union
EC Directive, 2000/36 for chocolate, including plain chocolate, milk chocolate and white choc-
olate was introduced in 2000 and implemented on 3rd August 2003, to simplify and harmonize
existing legislations in nine member states. The main objective was to create single market
for chocolate in Europe without discriminating local legislations.

The legislation covers the basics of ingredient requirements. Here, we will only focus on the
use of vegetable fat in chocolate. Basically, vegetable fats are now permitted, subject to spe-
cific requirements and labeling, in all member states. The vegetable fat must be a CBE, which
complies with the regulation of below.

 Non-lauric and it should be rich in symmetrical triglycerides.

 Compatible with cocoa butter in any proportion.
 Obtained only by refining and/or fractionation from six permitted plant sources that
were discussed earlier.
 Maximum 5% CBE (w/w) is allowed to be added to chocolate, milk chocolate and white
chocolate, with a conspicuous and clearly legible statement, ‘contains vegetable fat in
addition to cocoa butter’. This statement should be in the same field of vision as the in-
gredients list, clearly separated from the list, in lettering at least as large and in bold,
with the sale name nearby.

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 Chapter 4: Product Application: Coating Fats

Codex
The Codex Alimentarius Commission (Codex) is the highest international body for food stand-
ards. It was established in the early 1960s and is a subsidiary of the UN Food and Agriculture
Organization (FAO) and the World Health Organization (WHO). CODEX STAN87-1981, Rev. 1-
2003, is the Codex standards for chocolate and chocolate products.

The Codex standard could be used as a reference for products sold to countries where specific
legislation does not exist. The use of up to 5% vegetable fat is permitted in both EU and Co-
dex, but it is not allowed in United States.

United States
Chocolate and related products legislation is administered by the US Food and Drug Admin-
istration, in the code of Federal regulations. Title 21 is for Food and Drugs, and Part 163 of
this title covers cacao products. Chocolate and its products are defined in different way.

Total cocoa solids Cocoa butter Total milk solids Milk fat (%) Vegetable fat
(dry)* (%) (min) (%) (min) (dry) (%) (min) (%)

Sweet chocolate 15 12 (max)

Semisweet (bittersweet
35 12 (max)
chocolate)

Milk chocolate 10 12 (min) 3.39

White chocolate 20 14 (min) 3.5

Milk chocolate &

10 12 (min) 3.39 No limited
vegetable fat coating
*as chocolate liquor

Table 4.5: Chocolate composition to meet US Standards

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 Chapter 4: Product Application: Coating Fats

Latin American countries

In Latin American countries like Argentina, Costa Rica and Mexico the allowed limit of CBE’s in
the chocolate is up to 5% in the recipe. They also allow the use of enzyme modified CBE used
in the chocolate recipe. For other countries like Chile, there is no upper limit as long as the
chocolate meets the cocoa solid content of 22%. In Brazil, no upper limit as long as it meets
the cocoa solids content of 20% and 25% for milk and dark chocolate respectively. Many
chocolate producers use up to 7 – 10% of CBE’s in their recipes.

Figure 4.7: CBE legislation in Traditional chocolate around the globe

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 Chapter 4: Product Application: Coating Fats

Enzymatic Cocoa Butter Equivalents (eCBE’s)

Conventional CBE is produced by blending of defined vegetable fats to get the chemical prop-
erty that mimics cocoa butter. A new technology put up by recent investments in Loders
Croklaan facility has provided opportunity to use enzymes to produce the so-called eCBEs.

The enzyme technology can reduce the dependency of exotic fats like Shea and Illipe, since
their harvesting is not guaranteeing a stable supply. But the cost as well as legislative re-
strictions (labeling concerns like hydrogenation) still favors conventional CBE over eCBE. In-
teresterification reactions catalyzed by lipase are carried out under relatively anhydrous con-
ditions. The use of an enzyme provides the opportunity for either random interesterification or
a so called 1, 3-random exchange. Interesterification between TAG-TAG, TAG-fatty acid ester,
or TAG-fatty acid is catalyzed by a variety of lipase enzymes.

Figure 4.8: Enzymatic 1,3 random exchange reaction

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 Chapter 4: Product Application: Coating Fats

CBE’s of IOI Loders Croklaan-Coberine™

The first CBE was Calvetta developed and launched by Loders Croklaan in the late 1950s. The
range of CBEs has expanded greatly since then and now includes some highly functional co-
coa butter improvers (CBI) like Coberine™ 901 etc.

Table 4.6: Melting Profile of Coberine™ Range

The above table shows the solid fat content of different CBEs and CBI. The effect of adding a
CBE such as Coberine™ 608 and CBI such as Coberine™ 901 to cocoa butter can be seen in
Figure below. Coberine™ 901 is quite a hard fat and it is recommended to use at least ~5%
inclusion on the total chocolate recipe to get extra hardness and bloom stability. Using higher
levels are more effective, but there will be waxier taste, therefore balancing both effects is
needed.

Cocoa Butter / Coberine™ 608 Cocoa Butter / Coberine™ 901

Table 4.7: SFC of blends with CBE and CBI with Cocoa Butter
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 Chapter 4: Product Application: Coating Fats

Advantages of Coberine™
Irrespective of changes in climate conditions in growing areas of raw materials over the year,
there will be consistency in the quality of Coberine™ throughout the year providing better con-
sistency and control for the confectionary manufacturers. Coberine™ range is 100% compati-
ble with Cocoa butter since they have similar chemical structures. This means irrespective of
whatever the mixing ratio, there will not be any difference in the product quality. Additionally,
CBEs are more economical in price compared to Cocoa butter.

4.1.3. Cocoa Butter Substitutes

Cocoa Butter and CBE are polymorphic and their chocolates need to be tempered before
moulding or enrobing; otherwise the chocolate will have crystallization issues and will quickly
result in fat bloom and loss of shine. As the chocolate confectionary industry became wider
and more competitive, producers were looking for range of product varieties, these manufac-
turers started looking for more economical and easier ways of making chocolate coating par-
ticularly one without tempering process. As a result the emergence of Cocoa Butter Substi-
tutes (CBS) was achieved, which were based on lauric fats but resembled the melting profile
of cocoa butter.

Lauric fats which include Palm Kernel oil and Coconut oil, consist of higher levels of lauric and
myristic fatty acid which naturally give a sharp melting profile and melt fully at body tempera-
ture to give a clean taste sensation. The melting profile and quality of CBS can be modified
using selective fractionation and hydrogenation to get differences in the slip melting point and
solid fat content. Lauric fats form stable β’ form of crystals and don’t need a tempering pro-
cess hence reduce production cost as well as handling concerns. They possess strong heat
resistance and good snap while tasting.

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 Chapter 4: Product Application: Coating Fats

CLSP™ Range from IOI Loders Croklaan

IOI Loders Croklaan provides a wide range of CBS with varying melting point and solid fat
content to suit the specific requirements of the individual customers. The brand name of
those CBS is called CLSP™ and it comes together with three digit numbers which shows the
hardness of the product as the number is higher. CLSP™ 555/E is an exception in the num-
bering system as it is considered to be the most steep melting, premium and very well-known
CBS available in the chocolate confectionary market. The technical team in IOI Loders
Croklaan could advise the right type of CBS by looking at the end application, processing con-
dition and cost.

Table 4.8: SFC of different CBS from IOI Loders Croklaan

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 Chapter 4: Product Application: Coating Fats

Challenges

Despite being very easy to use in the final application, CBS have their own disadvantages. As
per the legislation, products made using CBS can’t be called as “chocolate” but must be
named “compound coatings”. With respect to vegetable fats other than the cocoa butter, only
CBE’s are allowed (with certain restrictions on inclusion) to use in the chocolate recipe.

Since CBS is based on medium chain fatty acids like lauric fats, they are not compatible with
the long chain fatty acids based Cocoa butter. So the recipes need to be carefully composed
to avoid quality issues. The maximum limit of Cocoa butter in the recipe needs to be max 5%
calculated on the fat phase. Since Cocoa powder always has a small portion of Cocoa Butter
(~11%), making a high cocoa powder content coating will result in early bloom and shelf life
issues.

Manufacturers using the same production line for both traditional chocolate (containing Cocoa
Butter and/or CBE blend) as well as compound coating are advised to invest in separate stor-
age tanks and pipelines. Cleaning enrober and depositer is mandatory before changing the
production. Improper cleaning will result in fat bloom and other shelf life problems.

Another major concern when using CBS in the compound coating is the hydrolysis of the fat
resulting in a soapy off-taste. This in particular is clearly noticeable in lauric fats giving a pe-
culiar smell and taste. To avoid this generally CBS is not recommended in products which
have higher moisture content or water activity. Concern of lipase activity in the other ingredi-
ents used together with the compound coating is therefore a serious matter to be tackled.

Further, CBS contains a high concentration of saturated fats (up to 99%) compared to the
bench mark fats like Cocoa butter and Cocoa Butter Equivalents (around 65%). CBS is gener-
ally hydrogenated but mostly fully hardened so there is hardly or no trans fatty acid issue. IOI
Loders Croklaan also offer CBS’s which are non-hydrogenated that could be used in the com-
pound coating application.
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 Chapter 4: Product Application: Coating Fats

4.1.4 Cocoa Butter Replacer

With many concerns on CBS including the compatibility with Cocoa butter as well as the soapy
taste issues, a range of Cocoa Butter Replacer’s (CBR) was developed to counter these prob-
lems and still being non-tempering by nature. CBRs are derived from non-lauric fats like
Palm, Soyabean and Rapeseed oil.

They are produced by partial hydrogenation of above mentioned non-lauric oils resulting in
high level of trans-fats which possess very good functional benefits like sharp melting profile
and good stability. Further the trans-fats are stable at β’ form and therefore they don’t need
any tempering process. These two advantages help confectionary manufacturers to have
more versatile fat to play around with their innovative products.

Trans-isomers found in CBRs are long chain fatty acids and they possess better compatibility
with cocoa butter compared to the lauric based CBS. The tolerance limit of Cocoa butter in the
CBR coating recipe is 20% calculated on the fat phase. This gives advantage to use the cocoa
mass instead of just cocoa powder in the coating recipe, adding to the cocoa flavour.

Besides that CBR can be used in recipes with high moisture content without the concern of
soapy taste issue as they don’t contain Lauric fatty acids. Also CBRs possess better tolerance
towards the milk fat as well as the nut oil which may come in through the inclusion of the
nuts in the compound coating.

IOI Loders Croklaan provides a wide range of CBRs that are chosen depending on the type of
end use application. The brand name of CBRs from IOI Loders Croklaan is called as Couva™.
Certain Couva™ range are recommended only for enrobing while other types of Couva™ are
recommended for both moulding and enrobing. IOI Loders Croklaan’s Couva™ 760P is the
premium CBR which can be used for all type of confectionary coating applications starting
from panning, moulding, enrobing etc.
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 4. Product Application: Coating Fats

4.1.4 Cocoa Butter Replacer

Table 4.9: SFC of different CBRs from IOI Loders Croklaan

With the growing health concerns on the trans-fatty acids, IOI Loders Croklaan is proud to
present a range of low trans CBR which could be used for the compound coating application.
They are non-tempering fats but without the trans-fat content in the product. IOI Loders
Croklaan’s Couva™ 850NH is the first non-lauric, non-hydrogenated (low trans-fat) and non-
tempering confectionary fat launched in the market.

Here in IOI Loders Croklaan Asia, we provide a wide range of low trans as well as non-
hydrogenated Couva™ that will satisfy the needs of the confectionary manufacturers. You can
approach the respective marketing person of your region for more updates on the latest
launches in the low trans CBR range suiting your application.

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 Chapter 4: Product Application: Coating Fats

4.1.4 Cocoa Butter Replacer

Table 4.10: SFC of non-hydrogenated Couva™ Range

The non-hydrogenated Couva™ range is particularly of great interest among the customers
who would like to have a very clean label on their end products. In countries where by legisla-
tion trans-fats are not allowed to be imported like South Africa, these fats find great ad-
vantage with the required functionality.

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 Chapter 4: Product Application: Coating Fats

4.1.5 Coating Recipes

Recipes used in making traditional chocolate as well as compound coating are mainly formu-
lated depending on the type of fats used in the recipe, like their compatibility towards with
Cocoa butter. For example, fats like Cocoa Butter Equivalents (CBE) are 100% compatible
with Cocoa butter so they could be used at any given blends ratio but when fats like Cocoa
Butter Substitutes (CBS) are used because of their low compatibility with cocoa butter the
recipe needs to be carefully instructed. Some typical recipes are stated here.

Table 4.11: Coating Recipes using Coberine™ (CBE)

Traditional Dark Chocolate Traditional Milk Chocolate

Dark Super Coating Milk Super Coating

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 Chapter 4: Product Application: Coating Fats

Table 4.12: Compound Coating recipes using CLSP™ (CBS)

Dark Compound Coating

Milk Compound Coating

CBS compound coating should only use cocoa powder as using cocoa mass which contains
more cocoa butter will automatically leads to violating the 5% rule and consequently into
compatibility problem. The recipe also needs to be considered based on the fact that cocoa
powder does contain a small portion of cocoa butter in the range of 10-12%. So making dark
compound coating with very high percentage of cocoa powder like Dark Bitter Coating might
not be possible if CBS is used as the fat in this application.

Table 4.13: Compound Coating recipes using Couva™ (CBR)

Dark Compound Coating

Milk Compound Coating

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 Chapter 4: Product Application: Coating Fats

For the coatings made with Cocoa butter Replacer (CBR), since there is a 20% tolerance to-
wards cocoa butter up to 20% there is room to use cocoa mass in the recipe. These com-
pounds could provide better cocoa flavour and taste compared to CBS coatings due to the co-
coa mass presence. Therefore more possibility exist to make Dark Bitter coatings using this
fat.

The cooling conditions also vary for chocolate / CBE coating as well as non-tempering coat-
ings like CBR and CBS. For tempering coatings like Cocoa Butter and CBE, gradual cooling
condition is recommended. The centre zone of the cooling tunnel will be cooler compared to
the entrance and exit zone. But for the non-tempering coatings like CBS and CBR, rapid cool-
ing is recommended. The first zone of the cooling tunnel will be cooler for these types of com-
pounds.

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 Chapter 4: Product Application: Filling Fats

4.2 Filling Fats

Rapid development in product innovation increases the demand of functional fats ingredients
not only in the coating fat application but in the fillings application as well. Evolution in pro-
duction techniques especially machineries result in adding challenges to a specialty fat manu-
facturer to come out with a product that not only taste good, but also last longer and is flexi-
ble enough to perform well at a different type of processing.

IOI Loders Croklaan, having a long standing tradition in specialty fats technology, developed
filling fats by describing the requirements of fat should meet according to customers wishes in
briefing for the development departments.

4.2.1. Shell moulded fillings

These fillings are deposited in to a preformed chocolate shell. The fat content is generally 30-
45% and their structure varies from rather hard to very soft, depending on the properties of
the fat used. The requirements of the fat, although very wide, must fulfill the following condi-
tions:
1. The fat phase must be pourable at 30oC. If a higher moulding temperature is required
the chocolate shell will melt too much.
2. The fat should crystallize quickly during cooling to enable good backing off of the filled
shells without smearing.
3. The fat phase must give a homogenous mass of fine crystals for optimum structure and
flavor release. To achieve this, pre-crystallization of the filling needs to be done.

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 Chapter 4: Product Application: Filling Fats

CLSP™, Biscuitine™ and Creamelt™ range are excellent fats for this application but must be
paired up with the right coating fat to maximize its shelf life.

The choice of the right filling fats for shell moulded products also depends on the presence of
other fat containing ingredients, such as nuts, cocoa powder, cocoa mass and full cream milk
powder. The advised melting profile is approximately 45% for the N 20 and maximum 10% for
the N30.

4.2.2. Extruded Fillings

This type of fillings usually involves the production of a pre-crystallised mass which has a ra-
ther hard structure. This is then plasticized in a kneader directly before passing through an
extruder unit and being formed into the required shape. After cooling these products are en-
robed with chocolate or other confectionery items. Such products have a fat content of 30-
40%. The requirements of the fat are the following:

1. In order to maintain the right filling consistency the fat should not melt during knead-
ing/mixing.
2. There should be little post-crystallisation after extrusion. Post-crystallization can have
an effect on the consistency of the centre, and could lead to oil exudation. In case the
centre is enrobed, this would mean a high risk of the appearance of fat bloom.
3. There should be no melting during enrobing as this would lead to centre deformation.

Biscuitine™ and Creamelt™ range would be the most suitable as CLSP™ which is our lauric
filling fat could be too brittle for this type of application.

The above requirements lead to the choice of a hard steep melting fat. The advised melting
profile is approximately 60% for the N20, 20% for the N30 and 8% for the N35.

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 Chapter 4: Product Application: Filling Fats

4.2.3. Cool melting fillings

The cooling effect of a fat based filling relates to the fact that melting crystals extract approxi-
mately 70 times as much heat from the palate as it takes just to warm up the same amount
of oil by one degree Celsius.

The solid fat content should thus be initially as high as possible and the temperature interval
over which this melts be very short several degrees below body temperature. The heat trans-
fer from the palate to the centre is rapid and this enhances the cooling effect. High fat con-
tents in the filling recipe are required to enhance the cooling effects. Due to the quick melting
range at low temperatures, it is very difficult to enrobe cool melting centres. Usually they are
shell moulded or wrapped as such.

CLSP™ and Creamelt™ due to their steeper melting curve offer a good choice for this type of
fillings. This premium cool-melting effect is obtained by selectively fractionated fats. The ad-
vised melting profile is approximately 60% for the N20, 40% for the N25 and 0% for the N30.

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 Chapter 4: Product Application: Filling Fats

4.2.4. Aerated fillings

The incorporation of air into the centres has been practiced for many years since now. The
key requirement for aeration is that at the whipping stage or some solid fat is present in the
fat phase. This is because of the stabilising effect crystals have on the foam produced by
keeping apart the air bubbles and preventing them from growing bigger and collapsing the
foam. The foam produced should be stable for further processing such as depositing, backing
off etc. The fat should have a fine crystal structure to enable it to do this optimally. Due to
the low density of the fillings produced, flavour release and cool eating sensation can be al-
tered. In order to improve flavour release, a stronger flavouring is sometimes required. A
possible loss in coolness after aeration can be restored by increasing the fat content or by us-
ing dextrose in the recipe. All IOI Edible Oils ranges can be used for this type of application.

The above requirements lead to the choice of a fat that will crystallise gradually during the
aeration process in order to ensure a high overrun. The choice of the fat will be fully depend-
ent on the type of aeration process used and particularly on the residence time and the tem-
perature during this process.

Non-polymorphic fats with a steep melting behaviour are suitable fats for this purpose. The
advised melting-profile is approximately 40% for the N20, 20% for the N30 and 6% for the N35.

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 Chapter 4: Product Application: Filling Fats

4.2.5. Biscuit and wafer fillings

Biscuit and wafer fats have many similar requirements such as serving as an adhesive and
glue the cream filling to the biscuit or the wafer. The fat should also have enough structure
to avoid being squashed out of the sides of the product when bitten. Generally these fats are
also aerated to a varying extent so the ability to produce a physically stable whipped product
is required.

However, they differ in the characteristics required for texture. A wafer is a soft light confec-
tion and the cream should be produced with a fat which reflecting this and offering a good
quick flavour release. In comparison a biscuit requires a harder bite and the cream therefore
requires more strength.

Consuming biscuit will take sometime in the mouth and therefore a more slowly flavour re-
lease from the fat may be preferred. A further area of difference lies in the production tech-
niques used. Wafers are generally made in “books” which are built up with alternate layers of
wafer and cream. These “books” are then cut into size. In the case of biscuits they are manu-
factured in single units and the cream is either deposited or stencilled onto one shell. In this
case no cutting is required. Depending on the customer requirements all ranges of IOI Edible
Oils filling fats could be used for biscuit and wafer fillings.

The advised melting-profile for wafer filling fats is approximately 50% for the N 20, 5% for the
N30. For biscuit filling fats, it should be approximately 55% for the N 20, 20% for the N30.

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 Chapter 4: Product Application : Bakery Applications

4.3. Bakery Application

Starting from convenient food to some of the most innovative foods, Bakery products have
wide scope in everyday food we consume. Fat is an essential ingredient in the bakery prod-
ucts. The way of inclusion and the type of fats changes with each product application like
Bread, Cake, Biscuit, Crackers, Pastry and Pie etc. IOI Loders Croklaan provides to the Bakery
Industry, a full basket of lipid solution ranging from shortenings to margarines with specific
functional, economical and processing benefits.

4.3.1. Shortening

We offer a wide range of shortenings which find specific functionality, applied from dough to
batter in a variety of bakery application. They “shorten” or provide softer texture to the bak-
ery product and are considered an important ingredient to improve the shelf life and texture
of the final
product.
Shortenings from IOI Loders Croklaan Asia are available with different melting points and
packaging with choice of aerated and non-aerated texture to provide the desired functionality.
Shortenings with high melting points are used mainly in yeast leavened bakery products as
well as crackers. For applications like cream fillings and wafer fillings, low melting point short-
enings are preferred to avoid any waxy taste and to have better sensory characteristics.

4.3.2. Milk Fat Replacer

Other than the shortenings used in the bakery application, IOI Loders Croklaan Asia provides
Milk Fat replacers to substitute butter fat in the bakery application. Carabuta™ NH is a vege-
table fat which comes with essential flavour precursors of milk fat. As the flavour develops
exactly in the same way similar to milk fat when used in cooking processes, it can be used as
general purpose bakery fat to replace or extend dairy butter in applications like Biscuits,
Cookies, Tarts, desserts and other baked goods. 55
 Chapter 4: Product Application : Bakery Applications

4.3.2. Margarine and Hardstock

The invention of margarine dates back to 18 th century but there has been so many develop-
ments ever since, focused on not only providing cost savings with similar texture and taste
but also having extra functional properties against butter.

Marfat Range from IOI Loders Croklaan is specially formulated and texturized to impart excel-
lent plasticity, smooth texture and good melting characteristics with good butter flavour.
They contain more than 80% fat and are suitable for use in varieties of application like cakes,
biscuits, bread etc.

The latest trend, based on nutritional science, is finding ways to eliminate the trans-fat intake
and reduction of saturated fat (SAFA) content present in our diet. Reducing the saturated fat
content in the food has been there for decades now but the new Dietary Guidelines recom-
mend the replacement of saturated fats with unsaturated fats rather with trans-fat or carbo-
hydrate. Use of trans fat or carbohydrate can be even more harmful than Saturated fat.

IOI Loders Croklaan has pioneered the concept of providing Hardstock for making low saturat-
ed fat and non-hydrogenated (low trans-fat) margarines. These hardstocks provide extended
features in providing the right crystal network, hardness and plasticity which are the basic re-
quirements for a good margarine. These are non-hydrogenated fats that could be blended
with soft oils to have a clean label with better nutritional values for the margarine producers.
The ratio of hardstock and the soft oil varies as per the type of margarine that needs to be
produced.

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 Chapter 4: Product Application : Dairy Applications

4.4. Dairy Application

Dairy products are well balanced and high energy yielding food items. They have been con-
sumed extensively and find use in almost every cuisine throughout the world. With the growth
of industrialization and technology, butter fat being the most important and expensive con-
stituent of the dairy products has been often replaced with vegetable fats. Vegetable fats not
only provide economic solution but also in certain cases it offers special functional benefits
which could not be achieved through the butter fat.

Understanding the impact of fat functionality in each of the Dairy application, IOI Loders
Croklaan have customized variants of specialty fats that provide suitable characteristics re-
quired for each specific application of the end products.

4.4.1. Non-Dairy Creamers

Non-dairy creamers can be dry powder or liquid which is intended to substitute milk/cream in
coffee, tea and chocolate beverage. Non-dairy creamer usually contains high fat content up to
a range of around 20-50%. They provide extended shelf life properties and better solubility in
the beverages compared to milk powders. The fat imparts the texture, flavor and opacity to
non-dairy creamer. Lauric fats like CLSP™ 822 are often used for this application.

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 Chapter 4: Product Application : Dairy Applications

4.4.2. Ice cream Fats

Ice creams are frozen desserts having a long history as a popular dairy food item for all occa-
sions. In modern time, there has been different variant of frozen desserts available with dif-
ference in texture, taste and creaminess. Fat is one of the key components decisive for the
structure of the frozen desserts like ice cream. Fat content ranges from 8% to 16% depend-
ing on the type of ice cream.

Often lauric fats like CLSP™ 310 and CLSP™ 620 are used depending upon the texture re-
quirement for the final product. IOI Loders Croklaan also provides low SAFA and low trans so-
lutions with the non-lauric, non-hydrogenated Creamelt™ 500 being used in this application.
Creamelt™ 500 was nominated for the best healthy ingredient during the Gulfood 2012 exhi-
bition Awards ceremony.

4.4.3. Whipping Cream

Cream is a dairy product coming in different grades depending on the total fat content. Imi-
tation creams are produced by blending special vegetable fats depending upon the type of
end use application. Special fat with good crystallization characteristics and steep melting
profile is required for application like Whipping Cream. High solid content in low temperature
provides better aeration properties and stability for the whipping cream. Hardened lauric fats
like CLSP™ 923 and CLSP™ 926 are commonly used for this application.

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 Chapter 4: Product Application : Dairy Applications

4.4.4. Cheese

Cheese being an importance milk derivative, has a long history and it is produced throughout
the world in wide ranging flavors, textures and forms. Analog or processed Cheese has be-
come popular with its characteristic long shelf life and relatively inexpensive costs. Despite
being a protein structure, fat is important in changing the texture of analog cheese.

Loders Croklaan provides special fats that could give specific impart on the structure and
shape integrity during ripening process of the cheese. They are suitable in producing a variety
of cheese products like Feta cheese, Mozzarella cheese, Cream cheese etc.

These Cheese fats are suitable to influence the flavor release of the cheese with good melting
profile and required texture. Vegetable fats with very close similarities as that of milk fat in
their melting characteristics are available. They provide neutral taste and don’t interfere with
the final cheese flavor. Specific nutritional requirements like reduced saturated fat and low
trans-fat versions are available.

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 Chapter 4: Product Application : Dairy Applications

4.4.5. Filled Milk

With the steady increase in demand for milk products, filled milk has gained momentum as
they resemble milk but are more economical and possess better shelf life than the 100%
dairy butter fat based milk products. Filled Milk is produced by reconstituting the milk solids
with vegetable fat from the sources other than the dairy fat. Many variants of Filled milk is
available now in the market including,
 Evaporated Filled Milk
 Condensed Filled Milk
 Filled Milk Powders

The commonly used vegetable fats for the filled milk are hydrogenated as well as non-
hydrogenated lauric fats like palm kernel oil and coconut oil. Nutritionally, these vegetable
fats used in the filled milk are of concern with high content of saturated fats and trans fats.
Non-lauric fats like Creamelt™ 600 not only provide better nutritional value by being low in
saturated fats and trans fats, but also gives very good shelf life for the final products. It also
helps providing a clean label for the final products as they are non-hydrogenated fats.

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Reference

1. Arishima, T., McBrayer, T.-Manuf. Confect. June 2002, 65-76.

2. BERGER KG (2005). The Use of Palm Oil in Frying. Malaysian Palm Oil Promotion Coun-
cil, Selangor, Malaysia.
3. S. Chaiseri, P. Dimick: Dynamic Crystallization of cocoa butter. II. Morphological, ther-
mal, and chemical characteristics during crystal growth. J. Am. Oil Chem. Soc. 72
(1995) 1497–1503.
4. Sridhar, R.,Lakshminarayana –Journal of Oil Techn. Assoc. of India (1991) 23, 42-43.
5. Talbot, G.-‘The Magnificient Seven”-lecture at SCI conference on the EU Chocolate Di-
rective, York, May 2003.

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Contact details
IOI Loders Croklaan Oils Sdn Bhd
PLO 8&9, Jalan Timah,
Pasir Gudang Industrial Estate,
81700 Pasir Gudang,
Johor, Malaysia.
Phone : +607 381 8888
Fax : +607 252 6420
Email: Creativestudio.Asia@croklaan.com
Website: www.letscreatetogether.asia

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