Innovative emulsification and freeze-drying techniques for developing heat-resistant chocolates with tunable textures and sensory attributes

The development of heat-resistant chocolate that meets customer preferences has been a longstanding challenge for both industry and academia. This study presented an innovative method for producing freeze-dried (FD) chocolate with enhanced heat resistance by integrating emulsification and freeze-drying technologies without altering the chocolate composition. Cryo-electron microscopy and X-ray microscopy revealed a unique microstructure in the product, where water-soluble components, such as sugar, formed a matrix that encapsulated fat-soluble components such as cocoa butter, providing heat resistance up to 70 °C. The check-all-that-apply (CATA) sensory methodology shows that consumers also favor FD chocolate for its crispiness and non-stickiness. The emulsification process was crucial in the formation of a unique microstructure. Key parameters, such as the water/solid ratio, sugar/cocoa solid ratio and emulsification method, significantly influence the viscosity and stability of the oil-in-water (O/W) emulsion and the heat resistance, texture, and sensory properties of the resulting FD chocolate.