Physically Modified Plant Oils as Alternatives to Palm Fat: Effects on Physical and Flavour Properties of Chocolate Fillings

Palm and palm kernel oils are extensively utilised in food processing due to their unique properties, such as their semi-solid consistency at room temperature. However, growing environmental and social concerns regarding palm oil production have prompted the industry to seek sustainable alternatives to tropical or hydrogenated fats. This project investigated the use of plant oils and their emulsified and crystallised forms as potential substitutes for palm fat in light and dark chocolate fillings, with an emphasis on single-origin ingredients to align with clean-label trends. The emulsions were assessed for viscosity, firmness, colour, and key flavour and aroma profiles. Results demonstrated that palm fat alternatives performed effectively in dark chocolate fillings, with non-emulsified recipes achieving firmness comparable to palm fat. In contrast, light chocolate fillings exhibited reduced firmness at higher inclusion rates of alternatives, and emulsified products were prone to flocculation. Notably, pure oil formulations delivered promising outcomes at lower inclusion rates, as the firmness could be raised by 22.0%, likely due to vegetable oil and cocoa butter interactions influencing crystal morphology. Substituting palm oil with sunflower oil, either crystallised or emulsified, did not compromise the overall flavour. Future investigations should determine the maximum feasible level of palm fat substitution and investigate the potential of adding higher amounts of waxes and emulsifiers to enhance crystal formation and firmness.