Periods: Three

Period 1: Planning

Period 2: Manufacture

Period 3: Product Formulation

1. To familiarize the student with the principles of confectionery processing, using Caramel as the work experience.

2. To develop an appreciation for quality control procedures used in the confectionery industry,with application of those procedures used in caramel manufacturing.

The manufacture of high quality confectionery products is considered an "art" . Careful selection of raw ingredients and conscientious blending, cooking, and cooling is required to achieve consistent quality.

The flavor of caramel is dependent upon the quality and quantity of ingredients used. The body and texture is for the most part, dependent upon the ingredients used and the crystallization of sugar during the manufacturing process. Desirable crystallization is achieved through the development of very small nuclei which results in a high level of growth points in the mix. One method used to control crystal nuclei formation is rapid agitation during cooling. Another method is "fondant seeding". Properly applied, either method will result in desirable crystalline structure, but "seeding" achieves a somewhat finer crystal matrix.

Students will prepare a caramel product for coating popcorn. Consider three variables in formulation or process to demonstrate their effect on process and product characteristics.

1.Apply a thin coat of butter to marble cooling slab.

2. Add the proper amounts of sucrose, salt, and brown sugar into the cooking kettle and add water. Stare heating and stir until sugar is well dispersed.

3. Add corn syrup and continue cooking until a temperature of 298-300 F. is reached.

4. Stir in butter, shortening, or oil just before adding to the popcorn. Stir sufficiently to prevent scorching.

5. Pour directly onto popped corn in an oiled mixing kettle or in a mixing machine and stir continuously until blended.

6. Pour onto marble cooling slab and allow to cool.

If non-adhering pieces are desired, and to prevent formation of large corn and syrup chunks: (a) add syrup while very hot; (2) stir rapidly while mixing corn syrup; (3)

spray or coat corn-brittle mixture with melted vegetable oil or coconut oil as soon as all syrup has been added and continue stirring mixture or keep chunks separate until the syrup has set. Approximately 1/8 lb of additional coconut oil or hydrogenated vegetable oil will be required for this step.

Complete the following analysis on the laboratory sample, and on the provided commercial samples.

1. Determine the total solids and moisture content.

2. Observe the relative size and arrangement of crystals by microscopic examination.

3. Make a texture analysis of the caramel.

4. Sensory panel to evaluate the texture and flavor of the products