Periods: Three

Period 1: Planning

Period 2: Manufacture

Period 3: Product Assessment

1. To familiarize the student with the principles of confectionery processing with chocolate fudge as the work experience.
2. To develop an appreciation for the quality control procedures used in the confectionery industry, with application of those procedures used in fudge manufacturing.

Fudge is a confectionery product utilizing a combination of the four basic food components: Carbohydrate, Lipids, Protein and Water. The final flavor and attributes of the fudge is dependent on the quality of the raw materials chosen and their relative amounts. In its purest sense, most fudge is truly flavored caramel. That is, a caramelized sugar slurry to which milk protein and fat are added imparting body and final flavor. The ultimate flavor is then achieved by addition of other flavor/coloring agents such as chocolate, nuts, etc. Therefore, parameters which are important to all fudge manufactures are similar to those for caramel including the rate and size of sugar crystallization, final amount and type of lipid, moisture content, and time/temperature of the overall processs. To better understand how these parameters and how they affect the final product lets discusses the basic of fudge manufacturing.

Generally milk and sugar are combined in a kettle and brought to boil very slowly. This is the first and perhaps one of the most important steps. The slow rise to 212 F or 100 C (which ever you prefer) will protect the milk and sugar from scorching prematurely and thus providing burnt off flavors and clumps to the final product. 212 F is often reached fairly quickly when using milk as the starting point. The high moisture content of the milk gives a very thin (low viscosity) slurry to start which will heat very rapidly. This mix is continually heated under slow but constant agitation until a final temperature of ~238 F is reached. With the Boiling Point of Water at 212 F just how do we achieve 238 F and why is that temperature important? To make a long story short, the greater the amount of solutes in a liquid the higher the boiling point (Check your Basic Chemistry Notes). Therefore, as the slurry reaches a boil at ~215-220 F the rise in temperature will plateau. However, slowly the temperature will continue to rise as more and more moisture is lost by evaporation. Therefore, the temperature can serve as an indirect measurement for moisture content. Thus, when it reached 238 F the slurry has lost a significant amount of moisture resulting in a thick, hot, super saturated sugar/milk paste. This super saturated sugar slurry will be the beginning of your fudge. Butter can be added in the beginning with the sugar and milk or melted in after the initial heating. This is purely your choice and as long as a final temperature of ~238 F is reached it should not matter in the end.

What does matter is the fate of the super saturated sugar solution. Being so concentrated this slurry is prone to sugar crystallization (making big clumps). Improper cooling or scraping can cause this. While in this molten state it becomes our responsibility to direct the mode of sugar crystallization to a desired endpoint giving us a large amount of small crystals and thus a smooth final texture. We do this by ensuring the appropriate final temperature is reached and the amounts of lipid, sugar, and moisture are in the proper ratio as dictated by the formulation (So follow your recipe!!).

Chocolate generally consist of three main ingredients, sugar (55%), cocoa powder (10 %), cocoa butter (35 %). The listed percentages are a rough guideline and depend on the type and quality of the final chocolate.

**( Pay attention to the brand and type of chocolate as they are all different. Some may have too much or too little fat and this can really damage your final product!!!)

To these three main components lecithin is added as an emulsifier and vanillin as flavor. So, when we add chocolate we do not just add cocoa as some people believe. In fact more than anything else we are adding extra sugar and lipid as cocoa butter. With the temperature of the slurry being extremely high (~236 F) the chocolate is normally added in its solid form and melted into the fudge with mild agitation. As the chocolate melts and the slurry begins to cool it becomes important not to scrape the sides of the kettle as this will promote excessive sugar crystallization and thus poor texture.

At this point any additional flavor, nuts or anything else you may desire can and should be added prior to final cooling and setting.

These are the final three steps in fudge manufacture and must be executed properly to ensure good texture. By Casting I mean transferring the hot fudge mixture to a room temperature pan (glass or metal) or marble slab. Properly seeded molten fudge should begin to set up immediately upon cooling. This is because the proper heating and a slow cooling has seeded the proper sugar and fat crystal which begin to solidify upon contact with a cool surface resulting in a smooth texture.

**(The slower the cool the more likely it is that the proper crystal structure will set and a smooth texture achieved)

**(Never cool the fudge in a refrigerated environment)

While still hot the fudge can be whipped to incorporate air or simply allowed to slowly solidify resulting in a more dense final product. As the product viscosity increases it becomes important to shape the warm fudge into the desired shapes prior to final setting and cutting.

When the product has completely cooled to room temperature it is time to cut the fudge into its final presentable form. This can be whatever you desire. The final product should then be stored in a dry air tight environment for 24 hours prior to consumption. This aging process will allow for final crystallization and texture and flavor development.

Measure out the following Ingredients:

Sweet Condensed Milk 2000g

Butter 565g

Sugar 950g

Semisweet Chocolate 1250g

Light Corn Syrup 50mL

Vanillin 20mL

1. Combine SC milk, sugar, and butter in steam jacketed kettle. Stir continuously to avoid scorching. Monitor temperature.
2. When temperature reaches ~150⁰F add the vanillin while stirring.
3. Continue stir and heat until mixture has reached ~238⁰F.
4. At this point turn off steam and add chocolate. Stir vigorously while monitoring the temperature.
5. Add in the corn syrup while stirring.
6. Allow to cool to ~180-190⁰F while stirring.
7. At this point pour mixture onto the marble slab, within the mold.
8. After fudge starts to solidify (5-10 min.) begin to work the mixture by folding toward the center with the paddle (Form a roll). Do so until fudge has lost gloss and has set up well.
9. When fudge has solidified cut into 6 inch square pieces and allow them to cool until next period.

1. Organoleptic evaluation by sensory panel.
2. Color evaluation.
3. Moisture content.
4. Texture Analysis.

The sensory evaluation should also include information regarding product color and texture allowing for a correlation to the analytical determinations.