Ultrasound-assisted high throughput continuous extraction for complete fragmentation of cocoa beans into valuable fractions and their formulations thereof

摘要

A process for the complete fractionation of cocoa beans with ‘zero waste’ into various value-added ingredients, a composition comprising cocoa polyphones/procyanidins and soluble dietary fiber, and a water dispersible and sustained release formulation of cocoa polyphones with cocoa soluble dietary fiber capable of forming a colloidal dispersion of bioactive cocoa polyphones in gastric fluid.

主权项

1. A process for the complete fractionation of cocoa beans with ‘zero waste’ into various value-added ingredients comprising the steps of
a) (i) cutting, flaking and powdering the dried cocoa beans and their ultrasound aided extraction with aqueous admixture of polar organic solvents such as lower aliphatic alcohols or lower aliphatic ketones or water alone,
(ii) filtering to separate the solvent extract and residue and(iii) evaporating the solvent extract under reduced pressure to obtain a concentrate rich in polyphenols, procyanidins, theobromine, and other phytochemicals present in cocoa beans. b) (i) evaporating the concentrate mentioned under step (a) (iii) at greater than 100° C. for about 2 to about 7 hours.
(ii) blending with emulsifiers to produce dark free flowing viscous liquid for using as flavoring ingredient(iii) having a composition of 10 to 20% fat, 35 to 50% carbohydrates, 15 to 25% proteins and 3 to 6% theobromine c) (i) evaporation and concentration of the alcohol-water or ketone-water extract of cocoa mentioned in step a) (ii) to a dissolved solid content of about 4 to about 25%,
(ii) chromatographically separating said concentrated extract(iii) eluting the column with lower alcohols and acetone either alone or in combination with water(iv) evaporating the eluted filtrate under vacuum to obtain a free flowing procyanidin type B polymer-rich polyphenolic extract having a composition of 950 to 990 mg polyphenols and 10 to 50 mg theobromine. d) (i) evaporation and concentration of the alcohol-water or ketone-water extract of cocoa mentioned in step a) (ii) to a dissolved solid content of about 4 to about 25%,
(ii) chromatographically separating said concentrated extract(iii) eluting the column with lower alcohols and acetone either alone or in combination with water(iv) evaporating the eluted filtrate under vacuum to obtain a free flowing procyanidin type B polymer-rich polyphenolic extract having a composition of 700 to 800 mg polyphenols with not more than 10 mg/g (0.1%) theobromine as a de-theobrominated cocoa procyanidins. e) (i) washing the chromatography column after step d) with demineralized water and collection of column wash
(ii) concentration of the column wash(iii) evaporating the column wash(iv) extraction of the concentrated column wash with ethyl acetate.(v) partition of ethyl acetate layer with acidified water.(vi) spray drying to get a theobromine-rich powder having a composition of not less than 400 mg/g theobromine f) (i) extracting the concentrate obtained in step a) (iii) with ethylacetate
(ii) partitioning the ethylacetate layer with acidified water(iii) concentration and spray drying the acidified water layer to get an extract having a composition of 300 to 500 mg/g theobromine 70 to 100 mg/g caffeine and 70 to 100 mg/g epicatechin containing extract without higher oligomeric procyanidins (g) drying the residue left after solvent extraction in step (a) under vacuum to produce a unique composition of de-bittered dietary fiber and proteins of cocoa suitable for food applications h) ultrasound aided enzymatic extraction of the total dietary fiber of cocoa obtained in claim 1(g) to selectively extract the soluble dietary fiber of cocoa beans with the steps comprising
(vi) Mixing the dietary fiber obtained from step 1(g) with 10 times of water(vii) Treatment with amylase, amyloglucosidase and proteases under optimum pH conditions(viii) Ultrasonication below 60° C.(ix) Filtration and concentration of the filtrate(x) Precipitation with alcohol and drying under reduced pressure to get soluble dietary fiber. i) (i) digesting the protein rich cocoa dietary fiber obtained in step 1 (g) with alkaline solution.
(ii) centrifugation and acidification of the supernatant solution to acidic pH with dilute mineral acids to precipitate cocoa beans proteins.(iii) adjusting pH and membrane filtration and spray drying to get cocoa proteins. j) treating proteins obtained under claim 1 (g) with proteases enzymes under ultrasonication followed by spray drying to provide cocoa protein hydrolysates for functional applications.
(i) preparation of water solution of cocoa polyphenols prepared under 1(c) and soluble fiber prepared under 1(h) separately(iv) mixing them in the presence or absence of other soluble fibers under high pressure homogenization conditions.(v) spray drying to provide unique composition of cocoa fiber encapsulated cocoa polyphenols compositions.