Enhancing cocoa butter crystallization through high-intensity ultrasound processing

High-intensity ultrasound (HIU) is a promising technique for tailoring the crystallization and functional properties of fats such as cocoa butter (CB). This study aimed to elucidate how specific HIU parameters-probe diameter (3.2 or 12.7 mm), amplitude (20-80 %), and sonication time (5-30 s)-affect the isothermal crystallization, melting behavior, texture, rheology, and solid fat content of CB after 24 h at 22 °C. Increasing acoustic energy significantly modified CB structure. Sonication at 40 % amplitude for 15 s with the 3.2 mm probe produced a dense, highly elastic crystal network, increasing storage and loss moduli, hardness (121.65 ± 18.08 N), and melting enthalpy (137.56 ± 1.97 J/g). Using the 3.2 mm probe, hardness increased progressively between 14 and 46 W, peaking at 44 W. In contrast, with the 12.7 mm probe, hardness slightly decreased at 44 and 150 W (101.29 ± 6.26 and 106.63 ± 13.70 N). These findings demonstrate that precisely controlled HIU can accelerate secondary nucleation, promote organized crystal networks, and enhance CB rheological and thermal stability, supporting the design of tailored fat-based products.