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Caramels, Fudge & Toffee

Randy Hofberger
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
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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.
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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 key
driver 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
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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

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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

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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
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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)

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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

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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

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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)
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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
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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
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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
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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!
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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
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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

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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
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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
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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
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Caramel Processing
Five basic unit operations
1)
2)
3)
4)
5)

Pre-Mixing
Emulsification
Cooking / Caramelizing
Cooling
Forming
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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
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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

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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
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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

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APV BAKER CARABLEND CARAMEL COOKER

YYP CARAMEL COOKER

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

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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

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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
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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

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HOHBERGER FONDANT BEATER

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

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