Patent Description:
Macarons are small round airy and crispy dough cookies that adhere to each other by means of a soft filling. The dough biscuits, also called shells, have a flat bottom and a convex top. Characteristic of the shells is the so-called "foot", a layer with an airy texture formed just above the flat bottom of the shell.

This foot is created because the macarons are dried before they are baked. This creates a harder layer or crust on the outside of the shell that is exposed to the air. Moisture will try to evaporate from the shell during baking. Since this vapor cannot escape along the formed crust, the shell is pushed upwards to allow the vapor to escape. To guarantee the uniformity and organoleptic properties of the macarons, it is not only important that the macaron always has the same composition and dimensions, but also that this foot always has the same proportions.

However, this is very difficult to achieve, since not only the composition of the dough, but also the drying and baking process are extremely important to obtain a shell with uniform dimensions and a uniform foot.

The present invention aims to find a solution for at least some of the above problems.

Document <CIT> discloses a prior art macaron (and the method for its manufacture) consisting out of two shells made from a dough, and a filling, each shell having a flat bottom and a convex top.

The invention relates to a method for producing macaron shells with a foot. More particularly, the invention relates to a method according to claim <NUM>, wherein a dough is made that comprises at least a sugar, egg whites and almonds, wherein the different ingredients of the dough are combined and mixed, wherein a dough with a density between <NUM> grams and <NUM> grams per liter is obtained, wherein in a first step the dough is sprayed into individual shells on a conveyor belt, the shells are then transported through a drying tunnel where the shells undergo a drying step and wherein the shells are then transported through a baking tunnel where the shells undergo a baking step, where the ratio between the diameter and the height of the shell immediately after spraying the dough into separate shells on the conveyor belt is between <NUM> and <NUM>, the ratio between the diameter and the height of the shell immediately after transport through the drying tunnel is between <NUM> and <NUM> and the ratio between the diameter and the height of the shell immediately after transport through the baking tunnel is between <NUM> and <NUM>. Preferred embodiments of this method are presented in claims <NUM> to <NUM>.

The inventors have discovered that when the shells meet the aforementioned ratios between diameter and height of the shell at these specific steps, a shell with the ideal dimensions and the ideal proportions of the foot is obtained.

The invention relates to a method for producing macaron shells.

The terms 'comprise', 'comprising', 'consist of', 'consisting of', 'provided with', 'have', 'having', 'include', 'including', 'contain', 'containing' are synonyms and are inclusive or open terms that indicate the presence of what follows, and which do not exclude or prevent the presence of other components, characteristics, elements, members, steps, as known from or disclosed in the prior art.

In a first aspect, the invention relates to a method for producing macaron shells with a foot, wherein a dough is made that comprises at least a sugar, egg whites and almonds, wherein the different ingredients of the dough are combined and mixed, wherein a dough with a density between <NUM> grams and <NUM> grams per liter is obtained, in which in a first step the dough is sprayed into individual shells on a conveyor belt, the shells are then transported through a drying tunnel where the shells undergo a drying step and wherein the shells are then transported through a baking tunnel where the shells undergo a baking step, wherein the ratio between the diameter and the height of the shell immediately after spraying the dough into separate shells on the conveyor belt is between <NUM> and <NUM>, preferably between <NUM> and <NUM>, the ratio between the diameter and the height of the shell immediately after transport through the drying tunnel is between <NUM> and <NUM>, preferably between <NUM> and <NUM>, and the ratio between the diameter and the height of the shell immediately after transport through the baking tunnel is between <NUM> and <NUM>, preferably between <NUM> and <NUM>.

The density of the dough is measured in a container with a rounded bottom, where the weight obtained is converted by the amount of water (in grams) that fits in the same container. In a preferred embodiment, the sugar is selected from granulated sugar and powdered sugar or a combination thereof. In a preferred embodiment, the sugar comprises both granulated sugar and powdered sugar, preferably in a ratio between <NUM> and <NUM>.

Macarons are small round airy and crispy dough cookies that adhere to each other by means of a soft filling. The dough biscuits, also called shells, have a flat bottom and a convex top. Characteristic of the shells is the so-called "foot", a layer formed just above the flat bottom of the shell.

This foot is created because the macarons are dried before they are baked. This creates a harder layer or crust on the outside of the shell that is exposed to the air. Moisture will try to evaporate from the shell during baking. Since this vapor cannot escape along the formed crust, the shell is pushed upwards to allow the vapor to escape. In this way, the macaron gets a more closed visible surface (at the level of the harder layer) while the internal part that makes contact with the filling (at the level of the foot) is airier. So there is a significant difference between the filling, the part of the shell that contacts the filling and the outer visible shell of the shell. To guarantee the uniformity and organoleptic properties of the macarons, it is not only important that the macaron always has the same height and diameter, but also that this foot always has the same proportions. Not only the initial dose and the composition are important here, which determines the ratio between the diameter and the height of the shell immediately after the dough has been sprayed into individual shells on the conveyor belt, but also the ratio between the diameter and the height of the shell immediately after transport through the drying tunnel, as this also determines the size of the harder layer (the crust) before the baking process and evaporation begins, which pushes the shell upwards and forms the foot. Also important is the ratio between the diameter and the height of the shell immediately after transport through the baking tunnel, when the baking process is over and this determines the dimensions of the final shell and the foot.

The inventors have discovered that in order to obtain a shell with the ideal dimensions and the ideal proportions of the foot, the ratio between the diameter and the height of the shell immediately after spraying the dough into separate shells on the conveyor belt is between <NUM> and <NUM>, preferably between <NUM> and <NUM>, the ratio between the diameter and the height of the shell immediately after transport through the drying tunnel is between <NUM> and <NUM>, preferably between <NUM> and <NUM>, and the ratio between the diameter and the height of the shell immediately after transport through the baking tunnel is between <NUM> and <NUM>, preferably between <NUM> and <NUM>. When the shells meet the aforementioned dimensions at these specific steps, a shell with the ideal dimensions and the ideal proportions of the foot is obtained.

In a preferred embodiment, the temperature in the drying tunnel is between <NUM> and <NUM>. This temperature is sufficiently high to form the crust on the air-exposed surfaces of the shell, but on the other hand it is also not too high, since then the evaporation process would already start, which would counteract the formation of the crust.

In a preferred embodiment, the shells are transported through the drying tunnel for <NUM> to <NUM> minutes. This duration is sufficiently long to start the initial formation of the harder layer.

The shells are then transported through a baking tunnel. In a preferred embodiment, the baking tunnel comprises at least <NUM> temperature-controlled compartments, wherein the temperature in the first compartment is between <NUM> and <NUM> and the temperature in the other compartments being between <NUM> and <NUM>. Because the temperature in the first compartment is between <NUM> and <NUM>, the shell can dry even further and the harder layer can harden sufficiently to prevent the escape of the vapor in the other compartments, where the temperature is between <NUM> and <NUM>. The higher temperature in the other compartments ensures that the shell is baked properly, whereby the formed vapor in the shell ensures that the shell is pushed upwards, and the foot is formed.

In a preferred embodiment, the shells are transported through the baking tunnel for <NUM> to <NUM> minutes, with the shells remaining in the first compartment for at least <NUM> minutes. This period of time in the first compartment at a temperature between <NUM> and <NUM> is necessary to allow the shell to dry even further and the harder layer to become sufficiently hard in order to prevent the escape of the vapor in the other compartments. During the residence time in the other compartments at a temperature between <NUM> and <NUM>, the shells are given sufficient time to bake out and form the foot with the correct properties. Important in the baking process is that the temperature is not too high, because too high a temperature will cause too much evaporation and steam formation of the moisture in the shell, which could cause the crust to crack.

In a preferred embodiment, the shells are transported after baking through a cooling tunnel where the shells undergo a cooling step, wherein the temperature in the cooling tunnel is between <NUM> and <NUM>. This cooling step ensures that the shells cool down quickly and become harder, giving them their crispiness.

In a preferred embodiment, the shells are transported through the cooling tunnel for <NUM> to <NUM> minutes. This period of time is long enough to cool the shells sufficiently, yet not too long so that the cooling process remains economically viable.

In a preferred embodiment, the shell dough comprises at least <NUM>% (m/m) almonds and the dough is prepared by separately producing a meringue at a temperature of <NUM>-<NUM> and an almond dough at a temperature of <NUM>-<NUM>, to then mix the meringue and the almond dough at a temperature between <NUM>-<NUM>.

Preferably, the meringue has a density between <NUM> and <NUM> grams per liter, preferably between <NUM> and <NUM> grams per liter, the almond dough has a density between <NUM> and <NUM> grams per liter, preferably between <NUM> and <NUM> grams per liter and the final macaron dough has an average density between <NUM> and <NUM> grams per liter, preferably between <NUM> and <NUM> grams per liter.

In a preferred embodiment, the average water activity of the dough decreases by at least <NUM>% between spraying the dough onto the conveyor belt and the end of the baking step.

The water activity is a measure of the amount of free water present in a product. The aw value is determined when the relative humidity around a product is stable. The aw value is a dimensionless unit. The aw spectrum runs from <NUM> to <NUM>. An aw value of <NUM> indicates that there is no free water in the product. For pure water, an aw value of <NUM> is the result.

An aw meter is preferably used to measure the aw value. This meter contains a chamber that can be completely closed off. The sample is placed in the chamber and sealed. The aw meter uses a chilled-mirror dew-point technique to measure the water activity of a sample. The sample is equilibrated with a sealed chamber containing a mirror where condensation on the mirror can be detected. At equilibrium, the relative humidity of the air in the chamber is equal to the water activity of the sample. The temperature of the mirror is precisely controlled by a thermoelectric (Peltier) cooler. Detection of the exact point where condensation first appears on the mirror is done with a photoelectric cell. A beam of light is directed at the mirror and reflected into a photodetector cell. The photodetector detects the change in reflection coefficient when condensation occurs on the mirror. The dew point sensor measures the dew point temperature of the air in the sealed chamber, and the infrared thermometer measures the temperature of the sample. From these measurements, the relative humidity of the headspace is calculated as the ratio of the dew point temperature to the saturation vapor pressure at the sample temperature. When the water activity of the sample and the relative humidity of the air are in equilibrium, measurement of the headspace humidity gives the water activity of the sample.

As described above, macarons consist of two crunchy almond cookies, which are somewhat chewy inside, and are stuck together with a soft filling. The contrast between the crispy outside, the slightly chewy inside and the soft filling is characteristic of the macaron. With such a drop in water activity, sufficient free water has evaporated and the shell has sufficiently baked out.

In what follows, the invention is described by way of non-limiting examples illustrating the invention, and which are not intended to and should not be interpreted as limiting the scope of the invention.

To prepare macaron shells, a dough is made that includes granulated sugar, powdered sugar, egg whites and almonds and has a density of about <NUM> grams per liter. The dough is then sprayed into individual shells on a conveyor belt, wherein the ratio between the diameter and the height of the shell immediately after spraying the dough is <NUM>. In a next step, these shells are transported through a drying tunnel where the shells undergo a drying step, wherein the ratio between the diameter and the height of the shell immediately after transport through the drying tunnel is <NUM>. The temperature in the drying tunnel is approximately <NUM> and the shells are transported through it for <NUM> minutes. This temperature is sufficiently high and the duration of the transport is long enough to form the crust on the air-exposed surfaces of the shell, but on the other hand is also not too high and too long, since then the evaporation process would already start, which would counteract the formation of the crust.

The shells are then transported through a baking tunnel where the shells undergo a baking step. The baking tunnel has <NUM> temperature-controlled compartments, wherein the temperature in the first is about <NUM> and the shells are transported through this for about <NUM> minutes and wherein the temperature in the other compartments is between <NUM> and <NUM> and the shells are transported through this for approximately <NUM> minutes. Because the temperature in the first compartment is only <NUM>, the shell can dry further and the harder layer can harden sufficiently in order to prevent the escape of the vapor in the other compartments, where the temperature is higher. The higher temperature in the other compartments ensures that the shell is baked properly, whereby the formed vapor in the shell ensures that the shell is pushed upwards and the foot is formed.

Important in the baking process is that the temperature is not too high, because too high a temperature will cause too much evaporation and steam formation of the moisture in the shell, which could cause the crust to crack. The ratio between the diameter and the height of the shell immediately after transport through the baking tunnel is approximately <NUM>.

Claim 1:
A method for producing macaron shells, wherein a dough is made that comprises at least a sugar, egg whites and almonds, wherein the different ingredients of the dough are combined and mixed, wherein a dough with a density between <NUM> grams and <NUM> grams per liter is obtained, wherein in a first step the dough is sprayed into individual shells on a conveyor belt, the shells are then transported through a drying tunnel where the shells undergo a drying step and wherein the shells are then transported through a baking tunnel where the shells undergo a baking step, wherein the temperature in the drying tunnel is between <NUM> and <NUM> and the shells are transported through the drying tunnel for <NUM> to <NUM> minutes and wherein the temperature in the baking tunnel is between <NUM> and <NUM> and the shells are transported through the baking tunnel for <NUM> to <NUM> minutes, characterized in, that the ratio between the diameter and the height of the shell immediately after spraying the dough into separate shells on the conveyor belt is between <NUM> and <NUM>, the ratio between the diameter and the height of the shell immediately after transport through the drying tunnel is between <NUM> and <NUM> and the ratio between the diameter and the height of the shell immediately after transport through the baking tunnel is between <NUM> and <NUM>.