we are developing new protein enriched wafer. To get the optimum level of protein content, we put 25% milk protein isolate inside of the filling, but our main problem is how to get the filling to be more spreadable? While spreading protein enriched filling, it was cracking and the overall look of the wafer was not nice after cutting the wafer block. So does anyone have some idea how to get better filling properties?
High level of protein gives harder filling. Can you use a softer fat? What do you use now as filling composition?
Yes, you can try sowter fat or replace some powder components with higer fat content in recipe. You can try with different protein source also.
I am not sure if the problem is that the protein particles are big and stick to roll scrapper (impacting application), or if the cream became too solid.
I'd suggest refining your protein to a smaller particle size (or buying it smaller). It is possible that you have to increase fat content after that, due to higher surface area for the fat to cover. Reducing sugar particle size might also help. Also, try increasing cream temperature, if possible, or increase/change emulsifier. If you are using rework, try reducing its quantity.
Besides above recommendations for changing fat, consider cream application through a manifold, instead of roll or film. It is common for aerated creams, and wafer equipment companies normally have this option.
There are companies that have solutions for oil in filling for wafers instead of fat, based on reducing particle size, so oil would get 'trapped' inside filling, thus not migrating to wafer sheet. That would be a more costly solution, and there still some risk of oil to migrate and get rancid due to air exposure.
viscosity in high protein fillings can be optimised with the inclusion of a suitable emulsifier. It's difficult to recommend one without knowing the details but our Proteins R&D team would be happy to discuss with you further. Gwen