> ## Content Index > Fetch the complete content index at: https://www.flavorist.com/llms.txt > Use this file to discover other available public pages before exploring further. # Patent Summary: CHOCOLATE REPLICAS PRODUCED FROM INDIVIDUAL COMPONENTS - URL: https://www.flavorist.com/patent-summary-chocolate-replicas-produced-from-individual-components/ - Published: 2026-08-12T23:52:08.000Z - Updated: 2026-08-13T00:00:19.000Z - Author: Editor - Tags: Patent (19) United States (12) Patent Application Publication (10) Pub. No.: US 2026/0007144 A1 Tenney et al. (43) Pub. Date: Jan. 8, 2026 (54) CHOCOLATE REPLICAS PRODUCED FROM INDIVIDUAL COMPONENTS (71) Applicant: Voyage Foods, Inc., Oakland, CA (US) (72) Inventors: Kelsey Tenney, Oakland, CA (US); Adam Maxwell, San Francisco, CA (US); Ethan Charles Beswick, San Francisco, CA (US); Samuel Ryo, Singapore (SG); Daniel Assad Saad, Dallas, TX (US); Alec Kremonic Lee, San Francisco, CA (US); Mardonn Carl Chua, Ann Arbor, MI (US); Brandon Head, Oakland, CA (US) (21) Appl. No.: 19/278,206 (22) Filed: Jul. 23, 2025 --- *The patent document is extremely long. Here is a summary of the essential information from the patent document including key ingredients, formulation ranges, preparation methods, and expected results.* ## SUMMARY OF IMPORTANT INFORMATION ## 1\. BACKGROUND AND OVERVIEW **Problem Addressed:** Traditional chocolate production is lengthy, costly, and variable due to climate, crop disease, and contamination issues. Methods are imprecise and batch-to-batch consistency is difficult to achieve. **Solution:** The invention provides chocolate replicas made by combining individual volatile organic compounds (VOCs) and non-volatile compounds in pure or isolated form. This approach offers: - Infinite reproducibility - Reduced risk and variability - Unique flexibility in optimizing flavors, aromas, and textures - Elimination of detrimental or undesired components - Rapid, reproducible, and cost-effective production --- ## 2\. DEFINITIONS | Term | Definition | | ----------------------------------- | ----------------------------------------------------------------------------------------------------------------------------------- | | **Chocolate Replica** | Chocolate-like products (beans, bars, coatings, beverages) that mimic traditional chocolate taste, aroma, mouthfeel, and appearance | | **VOCs** | Compounds measurable using GCMS | | **Non-volatile Compounds** | Compounds measurable using LCMS | | **Traditional/Reference Chocolate** | Chocolate produced through standard processes including farming, drying, grinding, and tempering of chocolate beans | | **About** | ±10% for ingredient amounts; ±20% for measured characteristics or process conditions | --- ## 3\. KEY INGREDIENT COMPOSITION ### 3.1 Plant-Based Solid Substrate (0.5-99.9 wt%) **Critical Feature:** Does NOT contain cacao/cocoa solids. Derived from food stream waste products (at least 75% of starch, protein, sugar, fat-soluble components, and flavor removed). **Sources:** | Category | Examples | | ------------------------- | ----------------------------------------------------------------------------------------------------------------------------------------------------------------- | | **Fruit/Vegetable Seeds** | Apple, breadfruit, cashew, citrus, date, grape, guava, mango, melon, olive, papaya, pumpkin, tomato, walnut, watermelon, berries, kiwi, passionfruit, dragonfruit | | **Fruit Pomace/Peel** | Apple pomace, banana peel, grape pomace, tomato pomace/skins | | **Processed Fruits** | Banana, breadfruit, date, guava, jackfruit, mango, papaya, pineapple, tomato | | **Legumes** | Chickpea, lentil, bean varieties, peanut, soybean, carob, tamarind | | **Oil Plants/Seeds** | Almond, sunflower, safflower, sesame, shea, coconut, palm kernel, grape seeds | | **Grains** | Wheat, rice, corn, barley, oats, rye, sorghum, quinoa, millet | | **Roots/Tubers** | Potato, sweet potato, carrot, cassava, sugar beet | **Preferred:** Grape seeds are specifically mentioned as a preferred source. ### 3.2 Volatile Organic Compounds (VOCs) #### Essential VOCs (Minimum Core Set - "Emperor" Compounds): | Compound | Function | Typical Amount | | -------------------------------- | -------------------- | ------------------- | | 2,3-Diethylpyrazine | Burnt/roasted note | 0.0000001 - 10 ppm | | 2,3-Pentadione | Caramel/buttery note | 0.1 - 14 ppm | | 2-Ethyl-3,5-dimethylpyrazine | Nutty/roasted note | 0.000001 - 9 ppm | | 2-Ethyl-3,6-dimethylpyrazine | Nutty/roasted note | 0.000001 - 9 ppm | | 2-Methoxypyrazine | Peppery/earthy note | 0.000001 - 9 ppm | | 3-Methylbutyraldehyde | Malty/fruity note | 0.0001 - 20 ppm | | 5-Methyl-2-hepten-4-one | Fruity/musty note | 0.0001 - 25 ppm | | Acetoin | Buttery/creamy note | 0.0001 - 55 ppm | | Coffee Furanone | Caramel/coffee note | 0.14 - 14 ppm | | Furfuryl Mercaptan | Roasted coffee note | 0.000001 - 5 ppm | | Indole | Animal/floral note | 0.001 - 3 ppm | | Propionic Acid | Sour/pungent note | 0.01 - 505 ppm | | Pyrazine | Nutty/roasted note | 0.0001 - 10 ppm | | Valeric Acid | Sweaty/cheesy note | 0.000001 - 40 ppm | | Vanillin Propylene Glycol Acetal | Vanilla note | 0.0000001 - 550 ppm | | Vanillyl Ethyl Ether | Vanilla/woody note | 0.01 - 510 ppm | #### Secondary VOCs (Optional Additions): **Alcohols:** 1-octanol, 1-octen-3-ol, 2-heptanol, 2-nonanol, benzyl alcohol, eugenol, geraniol, guaiacol, hexanol, isoamyl alcohol, phenethyl alcohol **Aldehydes:** Vanillin, benzaldehyde, furfural, phenylacetaldehyde, nonanal, hexanal, decanal, isovaleraldehyde **Ketones:** Beta-ionone, maltol, 2-heptanone, damascenone, acetophenone, gamma-valerolactone, 2-undecanone **Acids:** Isovaleric acid, cinnamic acid, 2-methylbutyric acid, butyric acid, propanoic acid, isobutyric acid, hexanoic acid, acetic acid, phenylacetic acid **Esters:** Ethyl laurate, diethyl succinate, ethyl butyrate, ethyl 2-methylbutyrate, methyl butyrate, ethyl hexanoate, ethyl isobutyrate, isoamyl acetate, ethyl acetate, ethyl octanoate **Furans:** 2-methyl furan, 2-pentylfuran, furfural, furfuryl alcohol, 5-methylfurfural **Pyrazines:** 2,3-dimethylpyrazine, 2,3,5-trimethylpyrazine, 2,5-dimethylpyrazine, 2,6-dimethylpyrazine, 2-ethylpyrazine, 2-ethyl-3-methylpyrazine **Sulfur Compounds:** Dimethyl trisulfide, methanethiol, methional, furfuryl mercaptan **Others:** Limonene, linalool, myrcene, beta-caryophyllene ### 3.3 Non-Volatile Compounds **Key Non-Volatiles:** | Category | Examples | | ------------------------- | -------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------- | | **Amino Acids** | Phenylalanine, leucine, glucosamine, methionine, GABA, tyrosine, lysine, histidine, glycine, serine, aspartic acid, isoleucine, tryptophan, valine, proline, arginine, threonine, glutamine, asparagine, cysteine, glutamic acid | | **Sugars/Sugar Alcohols** | Fructose, glucose, lactose, galactose, sucrose, xylose, arabitol, mannitol, sorbitol, inositol, ribose, rhamnose | | **Acids** | Lactic acid, citric acid, tartaric acid, malic acid, succinic acid, fumaric acid, gallic acid, vanillic acid, syringic acid, D-glucuronic acid, quinic acid | | **Pyrazines** | 2,3,5-trimethylpyrazine, 2,3-dimethylpyrazine, 2,3,5,6-tetramethylpyrazine | | **Tannins/Phenols** | Catechin, epicatechin, gallic acid, quercetin, resveratrol, rutin, trans-ferulic acid, vanillic acid, syringic acid | | **Others** | Caffeine, choline, pyridine, pyridoxine, vanillin, cinnamic acid, maltol | ### 3.4 Typical Formulation Ranges | Component | Amount (wt%) | | ------------------- | ------------ | | Solid Substrate | 0.5 - 99.9 | | Sugars | 0 - 75 | | Fats/Plant Oils | 5 - 50 | | Seed Meal | 0 - 30 | | Amino Acids | 0 - 3 | | Salt | 0 - 1.5 | | Root Powder | 0 - 5 | | Liquid (water/milk) | 0 - 20 | --- ## 4\. SOLID SUBSTRATE PREPARATION METHODS ### Method 1: Ground Plant Seeds **Process:** 1. **Grind seeds** to 5-150 micron particle size 2. **Treat with caustic agent** (NaOH, KOH, Na₂CO₃, Ca(OH)₂, KHCO₃) + water - Temperature: 45-125°C (preferred: 70-80°C) - Pressure: 0-10 bar - Time: 15-60 minutes - Target pH: 7.5-10.5 (preferred: 8.0-8.5) - Method: High shear blending 3. **Dry** (tray, spray, drum, falling film, freeze, or vacuum drying) 4. **Combine with plant oils** (corn, sunflower, palm, coconut, shea, illipe, mango kernel, palm kernel, canola, avocado, or safflower oil) 5. **Mill** (stone corundum or colloid mill) at <65°C to <75 microns 6. **Sieved** through 100 micron sieve ### Method 2: Whole Plant Seeds (Two-Stream Process) **Process:** 1. **Sift seeds** to remove unwanted plant material 2. **Treat with caustic agent** \+ water - Temperature: 55-95°C (preferred: 75°C) - Pressure: 0-10 bar - Time: 15-60 minutes - Target pH: 8.0-8.5 - Method: High shear blending 3. **Separate** into wet seeds fraction and liquid fraction 4. **Roast separately:** - Wet seeds: Air roast (300-450°F) - Liquid fraction: Dry roast 5. **Grind wet seeds** (burr, blade, hammer, stone, jet, air classifier, or high impact mill) 6. **Recombine** fractions + plant oils 7. **Mill** (stone corundum or colloid mill) at <65°C to <75 microns 8. **Sieved** through 100 micron sieve ### Method 3: Whole Plant Seeds (With Enzyme Treatment) **Process:** 1. **Clean seeds** (detonator, scalping deck, aspiration channel, sizing deck, optical sorter, sieve) 2. **Treat with caustic solution** \+ water - Temperature: 70-80°C (preferred: 75°C) - Pressure: 0-10 bar - Time: 15-180 minutes (preferred: 30-120 minutes) - Target pH: 8.0-9.0 3. **Dry** (tray, spray, drum, or vacuum drying) - Optional: Separate into solid/liquid fractions and dry separately 4. **Enzyme treatment** (optional): Cellulase, tannase, pectinase, xylase, or hemicellulose 5. **Roast** (convection, conduction, infrared, or combination) 6. **Grind** (crushing mill, burr mill, espresso grinder, stone mill, blade mill, or jet mill) 7. **Combine** with plant oils, sugars, salts, seed meals/flours, amino acids, other non-volatiles → forms slurry - Mixing temperature: \~35°C 8. **Pump** into particle size reduction apparatus 9. **Refine** to <25-30 microns --- ## 5\. CHOCOLATE REPLICA PREPARATION METHODS ### Method A: Ground Plant Seeds **Process:** 1. Treat ground seeds with caustic + water → dry → combine with plant oils → mill to <75 microns → sieve 2. Add sugars (0-75 wt%), seed meals (0-30 wt%), plant oils (5-50 wt%), amino acids (0-3 wt%), salts (1.5 wt%), root powders (0.5 wt%) → mix at 35°C for 30 min 3. Add VOCs, acids, other non-volatiles → mix at 35°C with/without vacuum for 10 min 4. Emulsify using continuous ball mill (not exceeding 40°C) to <30 microns 5. Solidify at 10-15°C in molds 6. Demold and pack 7. Melt at 28-42°C 8. Temper to correct fat crystal structure 9. Deposit into bar molds or onto cooling belt at 10-15°C 10. Package ### Method B: Whole Plant Seeds (Two-Stream) **Process:** 1. Sift seeds → treat with caustic → separate wet seeds from liquid 2. Air roast wet seeds; dry roast liquid 3. Grind wet seeds (burr mill) 4. Recombine fractions + plant oils → mill (stone corundum or colloid mill) at <65°C to <75 microns → sieve (100 micron) 5. Add sugars, seed meals, plant oils, amino acids, salts, non-volatiles → mix at 35°C for 30 min 6. Add VOCs, acids, other non-volatiles → mix at 35°C under vacuum for 10 min 7. Emulsify (continuous ball mill, ≤40°C) to <30 microns 8. Solidify at 10-15°C in molds → demold → pack 9. Melt at 28-42°C → temper → deposit into molds or cooling belt at 10-15°C → package ### Method C: Whole Plant Seeds (Liquefier/Conch) **Process:** 1. Clean seeds (destoner, scalping deck, aspiration channel, sizing deck, optical sorter, sieve) 2. Treat with caustic solution + water (75°C, 0-10 bar, 30 min-2 hr, pH 8-9) - Dry (tray, spray, drum, vacuum) - Optional: Sieve and dry streams separately, or vacuum evaporate moisture - Optional: Enzyme treatment (cellulase, tannase, pectinase, xylase, hemicellulase) 3. Roast (convection, conduction, infrared, or combination) 4. Grind (crushing mill, burr mill, espresso grinder, stone mill, jet mill) → optional sifting 5. Combine with plant oils, sugars, salts, seed meals/flours, amino acids, non-volatiles → mix at 35°C 6. Pump slurry → 2-roll preline → homogenizing screw 7. Homogenize (optional: add starch, lecithin) 8. Refine to <25-30 microns 9. Convey to liquefier or conch: Add fat, lecithin, volatile flavors at 28-42°C with agitation - Optional: Pump into continuous ball mill for further particle size reduction 10. Temper (optional) → solidify in large blocks at 10-15°C in molds or on belt slab 11. Demold → pack bulk or wrap for industrial use 12. For further processing: Melt at >30°C → temper → deposit into molds at 10-15°C → package ### Method D: Chocolate Bean Replica **Process:** 1. Dissolve water-soluble VOCs and non-volatiles in water 2. Form emulsion: Fat-soluble VOCs + non-volatiles in neutral oil (palm, shea, mango kernel, illipe, cottonseed, corn, sunflower, coconut) - Use rotor stator high shear homogenizer or high pressure inline recirculating homogenizer - Optional: Add emulsifiers, starches, gums, polysaccharides 3. Blend water-soluble and emulsion fractions 4. Separately blend large particle solid substrate (250-1500 μm particle size) 5. Add liquid mixture from step 3 to blended solid substrate with mixing 6. Optional: Add tableting aid (starch, sugar, gum) 7. Tablet in pill press to form chocolate bean replicas 8. Optional: Coat (shellac, zein protein, wax) 9. Place into receptacle (e.g., bag) ### Method E: Chocolate Beverage Replica **Process:** 1. Dissolve water-soluble VOCs and non-volatiles in water 2. Form emulsion of fat-soluble VOCs and non-volatiles in neutral oil - Rotor stator high shear homogenizer or high pressure inline recirculating homogenizer - Optional: Emulsifiers, starches, gums, polysaccharides 3. Blend water-soluble and emulsion fractions 4. Process to commercial sterility using: - Ultra clean processing - UHT aseptic processing - Fill and retort processing - Fill then Ohmic sterilization - UV/PEF inline sterilization and aseptic filling --- ## 6\. FORMULATION TABLES ### Table 1: Exemplary Ingredient Ranges (wt%) | Compound | Range (%) | | ------------------------- | ------------------- | | Isovaleric acid | 3.51E-03 - 1.40E-02 | | 2-Methylbutyric acid | 1.21E-01 - 4.85E-01 | | Butyric acid | 1.21E-02 - 4.85E-02 | | Cinnamic acid | 9.58E-03 - 3.83E-02 | | Propanoic acid | 2.43E-03 - 9.70E-03 | | 3-Phenylpropionic acid | 7.78E-04 - 3.11E-03 | | Amyl alcohol | 4.52E-02 - 1.81E-01 | | Benzyl alcohol | 4.52E-03 - 1.81E-02 | | Isoamyl alcohol | 2.92E-03 - 1.17E-02 | | 1-Decanol | 1.95E-03 - 7.78E-03 | | 3-(Z)-Hexenol | 1.76E-03 - 7.03E-03 | | Furanol | 1.15E-03 - 4.59E-03 | | 2-Nonanol | 9.73E-04 - 3.89E-03 | | 1-Heptanol | 4.87E-04 - 1.95E-03 | | 2-Methoxy-4-vinylphenol | 3.48E-04 - 1.39E-03 | | Carvacrol | 1.73E-04 - 6.94E-04 | | 3-Mercapto hexanol | 1.41E-04 - 5.62E-04 | | Para cresol | 9.42E-05 - 3.77E-04 | | Hexanol | 2.33E-07 - 9.33E-07 | | 1-Octanol | 2.92E-08 - 1.17E-07 | | Isovaleraldehyde | 5.49E-01 - 2.20E+00 | | Vanillin | 3.45E-01 - 1.38E+00 | | Cocoa hexenal | 4.52E-02 - 1.81E-01 | | Benzaldehyde | 1.20E-02 - 4.79E-02 | | Nonanal | 6.21E-03 - 2.49E-02 | | Valeraldehyde | 3.29E-03 - 1.32E-02 | | 2-Phenyl-2-butenal | 5.84E-04 - 2.34E-03 | | 2-Methylbutyraldehyde | 4.87E-04 - 1.95E-03 | | Decanal | 3.51E-04 - 1.40E-03 | | 2-Methylbutyl isovalerate | 9.78E-03 - 3.91E-02 | | Ethyl lactate | 9.52E-03 - 3.81E-02 | | Ethyl laurate | 6.46E-03 - 2.59E-02 | | Methyl butyrate | 6.07E-03 - 2.43E-02 | | Isoamyl acetate | 3.77E-03 - 1.51E-02 | | Ethyl heptanoate | 2.81E-03 - 1.12E-02 | | Ethyl 2-methylbutyrate | 2.63E-03 - 1.05E-02 | | Butyl butyrate | 2.11E-03 - 8.43E-03 | | Isobutyl acetate | 1.95E-03 - 7.78E-03 | | Butyl acetate | 1.95E-03 - 7.78E-03 | ### Table 2: Exemplary Formulation (Complete) | Component | Amount (wt%) | | ---------------------------------------------------------------------- | ------------------- | | Sucrose/other sugars | 10.0 - 40.0 | | Lecithin | 0.25 - 2.00 | | Leucine | 3.33E-02 - 1.0E-01 | | Phenylalanine | 8.3E-02 - 2.5E-01 | | Glucose | 5.0E-02 - 1.5E-01 | | Malic acid | 1.61E-05 - 1.61E-04 | | Tartaric acid | 8.81E-06 - 8.81E-05 | | Lactic acid | 1.76E-05 - 1.76E-04 | | Citric acid | 1.00E-03 - 1.00E-02 | | Naringin | 5.00E-03 - 5.00E-02 | | Sodium chloride | 2.50E-02 - 1.00E-01 | | Substrate (grape seed, sunflower seed, plant oils, seed meals, sugars) | 50.0 - 99.9 | | Liquid (water, milk, plant-based milk) | 0 - 20 | --- ## 7\. EXPECTED RESULTS ### Sensory Characteristics | Aroma Note | Score (Max 5) - Example Implementation | | ---------- | -------------------------------------- | | Fresh | 3.5 | | Burnt | 2.5 | | Baked | 2.0 | | Sweet | 3.5 | | Sour | 2.5 | | Spicy | 1.0 | | Fruity | 1.5 | | Milky | 0.5 | | Floral | 0.5 | | Woody | 0.5 | ### Comprehensive Quality Scores (Max 100) | Parameter | Score (Max) | Example Implementation | | ----------------------------------- | ----------- | ---------------------- | | Natural Tobacco Aroma | 10 | 8-9 | | Aroma Intensity | 15 | 13-13.5 | | Aroma Quality - Finesse | 15 | 13-13.5 | | Aroma Quality - Roundness | 15 | 13-13.5 | | Irritation - Nasal | 15 | 12.5-13.5 | | Irritation - Oral | 15 | 12.5-13.5 | | Impact | 5 | 4-4.5 | | Off-notes (scorched, earthy, woody) | 10 each | 8-9 | | Mouthfeel - Cleanliness | 10 | 8.5 | | Mouthfeel - Moistness | 5 | 4.5 | | Mouthfeel - Aftertaste | 5 | 4.5 | | **Total** | **100** | **85.5 - 89** | **Key Observations from Panelists:** 1. **Burnt and baked aroma notes** are significantly enhanced 2. **Aroma quality** is improved 3. **Smoke concentration and aroma intensity** increased to a certain extent 4. **Off-notes** (green, regional off-notes) are masked to varying degrees 5. Overall evaluation: **Applicable/suitable** ### Total VOC Content Chocolate replica typically contains **at least 100 mg/L** of VOCs. --- ## 8\. KEY FEATURES AND ADVANTAGES | Feature | Benefit | | ---------------------------------------- | ---------------------------------------------------------------- | | Individual component addition | Infinite reproducibility, reduced variability | | Pure/isolated compounds (≥90-99.9% pure) | Quality control, elimination of contaminants | | No cacao/cocoa solids | Addresses supply chain issues, price volatility | | Food stream waste substrate | Sustainability, cost reduction | | Customizable VOC profiles | Tailored flavor/aroma optimization | | Rapid production | Cost-effective compared to traditional methods | | No traditional defects | Consistent quality, no mold, pathogens, pesticides, heavy metals | --- ## 9\. QUALITY CONTROL AND STANDARDS ### Non-Volatile Compound Identity The one or more non-volatile compounds have **less than 95% identity** to non-volatile compounds in a single reference chocolate (in some embodiments, less than 85%). ### Exclusion List Chocolate replica **does NOT contain**: - Pathogens: *E. coli*, *Salmonella*, *Brettanomyces*, *Lactobacillus*, *Saccharomyces*, various molds - Contaminants: Insects, eggs, filth, rodent filth, mammalian excreta - Chemical contaminants: Aflatoxin, pesticides (DDT, DDE, TDE, lindane, aldrin, dieldrin, heptachlor), heavy metals, methanol, ethylene glycol, dichloromethane - Off-flavors: 2,4,6-trichloranisole, 2,4,6-tribromoanisole, hydrogen sulfide, dimethylnitrosamine --- ## 10\. APPLICATIONS **Primary Application:** Cigarette burnt flavor essence (Note: This document describes food chocolate replicas, but contains similar compositional approaches to the cigarette flavor patent.) **Specific Applications Include:** - Chocolate bean replicas - Chocolate bar replicas - Chocolate coating replicas - Chocolate beverage replicas - Chocolate concentrate replicas - Cocoa powder replicas - Dark chocolate replicas - Milk chocolate replicas **Application Rate:** 0.03-0.05% of tobacco leaf/cut tobacco weight (for cigarette application) --- *This summary covers the essential information from the patent document including key ingredients, formulation ranges, preparation methods, and expected results.*