Caramels, Fudge & Toffee
Randy Hofberger
Resident Course in
Confectionery Technology
Resident Course in Confectionery Technology
Caramel, Fudge & Toffee - Definitions
The primary ingredients of these products are sugars, corn syrups, fats and dairy ingredients
Caramels usually have a smooth, non-grained texture
Fudge has a short granular texture The brown stuff found on the outside of some
cookies is not really Fudge ! The US definition of Toffee is a hard candy
containing a dairy ingredient (butter, cream, condensed milk etc.) Examples ; English Toffee, Butterscotch, Butter Toffee
Resident Course in Confectionery Technology
Caramel, Fudge & Toffee - Definitions
In the UK, toffee usually refers to a hard caramel although the term is also applied to hard, sugar based products usually containing nuts. An old version of the word toffee was
Taffy now out of use except in Wales and in the USA, (Salt Water Taffy)
Caramels were invented in the USA around the turn of the 19th. century.
Resident Course in Confectionery Technology
Caramels-structure
A complex structure - a highly concentrated sugar solution containing emulsified fats
The structure also contains milk proteins dispersed throughout its mass
Textures vary from semi fluid to hard, moisture content is a keydriver of hardness, ranges from 6-20% moisture
Milk protein is a major influence on texture, typically 1 to 4% of product. The protein coagulates during cooking to provide body
Protein provides stand-up properties i.e. prevents cold flow At low end of moisture content range protein is less important
than total solids
Resident Course in Confectionery Technology
Fudge-structure
Two phase system sugar crystals surrounded by a continuous syrup phase
Water content is the main influence on hardness The crystal network provides the characteristic
short texture of fudge Not subject to cold flow due to crystalline structure
Resident Course in Confectionery Technology
Toffee-structure
An amorphous, glass like state basically a hard candy with fats emulsified into the syrup
The high fat content gives it a friable, crunchy texture
Toffees very often have nut or other inclusions added e.g. the almonds in English Toffee
Resident Course in Confectionery Technology
Major Raw Materials
Sugar Sucrose is the main sweetener and bulk raw
material In fudge the sugar content must be high
enough to allow crystallization White sugar mostly used a partial
replacement with brown sugar will add flavor Invert Sugar
Hydrolyzed sucrose - 76% solution Up to 5% for tender texture & humectancy.
fudge and helps control crystal size excess = stickiness
Resident Course in Confectionery Technology
Major Raw Materials
Corn Syrup Provide bulk, body and prevents (caramel) or controls
(fudge) crystallization Too much in caramel = Tough/chewy texture & cold flow Regular 42 DE most often used, Lower DE = Tough,
chewy texture Higher DE more tender but can lead to stickiness & lack of body
High Fructose corn syrup (42%) is very similar to invert in composition can be used as a 1:1 replacement (on a solids basis)
Resident Course in Confectionery Technology
Major Raw Materials
Milk Key ingredient for flavor & texture Milk protein reacts with reducing sugars in Maillard
reaction a major factor in developing the typical caramel flavor/color
Milk proteins provide body & stand up quality Several different proteins mainly casein, lactalbumin
and lacto globulin 80% of protein in milk is casein remaining 20% are whey
proteins Caramels contain 1-4% total protein
Resident Course in Confectionery Technology
Major Raw Materials
Milk products Fresh milk;
13% solids rarely used due to high moisture content.
Sweetened condensed whole milk; most commonly used 27% water, 44.3% added
sugar,8.1% protein, 8.7% milk fat, 11.4% lactose Seeded with fine lactose crystals
Sweetened condensed skim milk; 28% water, 42% added sugar,10% protein, 0.3% milk
fat, 16.3% lactose
Resident Course in Confectionery Technology
Major Raw Materials
Milk products Condensed milk & Evaporated milk;
Very similar products consisting of milk concentrated to around 33% solids. Contains 9% protein, 9% fat & 11.4% lactose (also available in skim versions in which fat has been removed)
Evaporated milk sold in cans, condensed milk in truckloads
Evaporated milk is a favorite in retail candy kitchens, gives a rich creamy flavor, must be added slowly to boiling batch to avoid curdling
Condensed milk used in large scale operations where plant is close to dairy high transportation costs short shelf life (10 days Max)
Resident Course in Confectionery Technology
Major Raw Materials
Milk products Milk Powders
Dried milk powders (whole or skim) can be used in caramel & fudge. May lead to rough texture & inferior flavor
Careful attention should be paid to reconstitution method. Premixing with sugar & using high shear mixer recommended and, ideally a 24 hour holding period to ensure maximum hydration
Available as spray or roller dried, usually roller dried is used (lower cost)
High & low heat versions available low heat is easier to reconstitute high heat better functionally
See attached paper on milk powders by T. Galloway
Resident Course in Confectionery Technology
Major Raw Materials
Milk products Whey powders & protein concentrates
Used as a substitute or partial replacement for milk in caramels & fudge. Protein 12.9% Lactose 73.5% Ash 8.0% (demineralized whey with lower ash is recommended)
Produces inferior product due to poor flavor, lack of body as the protein contains no casein
High lactose leads to excessive color development & can lead to rough texture if crystals form in finished product
Milk protein concentrates have lower lactose levels
Resident Course in Confectionery Technology
Major Raw Materials
Fats Contribute to the flavor & texture of fudge, caramel &
toffee. Provide a creamy mouth feel, influence the firmness and provide lubricity to prevent sticking to equipment during production and teeth during consumption
Milk fat contributes to the typical caramel flavor Is added as part of the milk ingredient, as dairy
butter or as anhydrous milk fat Other fats vegetable oils (usually hardened or
naturally hard) often incorporated as part of the formula. Most common are from soybeans, palm kernel, palm, coconut and cottonseed
Resident Course in Confectionery Technology
Major Raw Materials
Fats Fats should be well refined & free form off-flavors
Unlike butterfat, vegetable oils do not contribute to the flavor of the product
The melting point should not be far above blood heat or a waxy mouth feel will result Typically fats with melting points of 92F to 110F are used
Hard fats contribute to the texture of the caramel and help to prevent cold flow
The fat content should be sufficient to prevent sticking. Too much can lead to separation
The total fat in most caramel & fudge recipes is 10-15% but 6 20% can be found. English toffee up to 40% butter!
Resident Course in Confectionery Technology
Major Raw Materials
Emulsifiers Added to ensure adequate emulsification of the
fats into the aqueous phase. Milk contains natural emulsifiers
Soy lecithin by far the most commonly used emulsifier ca 0.25% of the batch weight
Mono-glycerides and / or Di-glycerides are sometimes used as emulsifiers, they also help to improve lubricity and are useful in low fat content formulae. Ca 1.0-2.0% of batch used
Resident Course in Confectionery Technology
Major Raw Materials
Starches, proteins, gums and gelling agents Starches sometimes used to provide body in
low protein formulae. Sufficient water must be added to ensure gelatinization during cooking (5 X the weight of starch)
Other materials used to add body in caramels include egg whites, soy proteins, wheat flour, gelatin and alginates
Resident Course in Confectionery Technology
Major Raw Materials
Salt Added to enhance the flavor of the other raw
materials 0.25 1.0% (including any salt from butter)
pH adjusting ingredients The caramel or fudge pre-mix should have a
neutral ph (6.8-7.0). A low pH can cause curdling of the milk & granular texture. Basic salts are added to adjust the pH
Sodium Bicarbonate most commonly used at around 0.3% of batch
Resident Course in Confectionery Technology
Major Raw Materials
Flavor Vanilla flavor is usually added to basic caramel
& fudge recipes Vanilla extracts, Vanillin or other synthetic
flavors Other natural and artificial flavors often added
e.g.. Licorice, Peppermint, Raspberry
Inclusions A wide variety of inclusions can be found
nuts, crisp rice, chocolate, marshmallows etc
Resident Course in Confectionery Technology
Caramel Processing
The simplest process is to use open kettles heated by steam or gas
Kettle constructed of copper or stainless steel and fitted with scrapers to prevent scorching caused by milk protein burning on the sides of the kettle
Copper kettles provide best heat transfer stainless preferred for sanitation
Copper can also catalyze rancidity in less stable fats leading to reduced shelf life
Resident Course in Confectionery Technology
Caramel Processing
Five basic unit operations
1) Pre-Mixing2) Emulsification3) Cooking / Caramelizing4) Cooling5) Forming
Resident Course in Confectionery Technology
Caramel Processing
Pre-Mixing Sugar, corn syrups, condensed milk,
water (if required), fats, emulsifiers and salt are blended and heated to melt sugar and fats
Should be heated to at least melting point of fats/emulsifiers + 10F
Usually heated to ca 160F
Resident Course in Confectionery Technology
Caramel Processing Emulsifying
A very important stage in caramel production, the fat must be very well homogenized into the liquid phase Usually achieved in a high shear mixing stage
between pre-mixing and cooking typically 10 to 20 minutes while maintaining temperature of 160 to 180F
Ultrasonic homogenizers can also be used Adequate emulsification is essential to
optimize flavor and to prevent fat separation during processing or storage
Resident Course in Confectionery Technology
Caramel Processing
Conventional Cooking and Caramelizing The emulsified batch is cooked with constant
scraping to the final temperature required to give the required final moisture content
During cooking the batch will caramelize and develop the characteristic flavor & color
Caramelization is time & temperature dependant, increase or decrease heat to adjust
A typical cooking time is 20 minutes Flavors are usually added at the end of
cooking after the heat has been turned off
Resident Course in Confectionery Technology
Caramel Processing
Continuous Cooking and Caramelizing There have been several different methods developed
to cook and caramelize continuously; some examples are A heated, four zone, open top barrel with a shaft
less scraper and an overflow weir to determine residence time and degree of caramelization
A scraped or wiped surface heat exchangers followed by retention stage at high temperature
A vertical cooking vessel with rapid agitation and controlled residence time
APV BAKER CARABLEND CARAMEL COOKER
YYP CARAMEL COOKER
Resident Course in Confectionery Technology
Caramel Processing
Cooling Caramel made by the batch process is
usually poured out onto a water cooled table and tempered with occasional folding to the desired plasticity
Caramel from a continuous process is usually passed over a water cooled wheel
Resident Course in Confectionery Technology
Caramel Processing
Forming Depending on the product being made the
caramel is transferred to the forming machine e.g Batch Roller / Cut & wrap Extruder Depositor (not pre-cooled) Bar former
Resident Course in Confectionery Technology
Fudge Processing
The fudge cooking process is the same as for caramel
Graining To produce the grained structure of fudge,
sucrose crystallization must be induced, the most comon methods are; Cooling without agitation (200F-130F) in a
water cooled kettle, then adding fondant to seed crystallization. Lower mixing temperatures = smaller crystal & smoother texture
Resident Course in Confectionery Technology
Fudge Processing
Graining (cont.) Using a flat bed beater
Pour cooked batch into a cream beater cool (water jacket in base) ca 100F. Start machine, the ploughs agitate the mass and crystallize the sugar. The mass will thin at end of process due to heat of crystallization
Fudge can also be made using equipment based on continuous beaters or heat exchangers designed for fondant production
HOHBERGER FONDANT BEATER
Resident Course in Confectionery Technology
Fudge Processing
Forming As with caramel there are many ways to
form fudge into a finished product, Extruding Bar Forming Depositing (starch or starchless) Filling into plastic or foil trays Cut and wrap Stamping into shapes
Top Related