Correlations Between Sensory Evaluations and Instrumental Measurements in Milk Chocolate with Varying Emulsifier Levels and Particle Sizes

This study was conducted to investigate and identify correlations among sensory and comprehensive consumer test results with rheological, textural, and tribological properties of milk chocolate in response to varying levels of particle size and emulsifier. To simulate realistic oral conditions, artificial saliva was incorporated into instrumental analyses. Rheological analysis revealed that increasing particle size and emulsifier concentration significantly reduced plastic viscosity, while emulsifier concentration alone increased yield stress due to structural reorganization within the fat phase. Tribological measurements demonstrated that larger particles increased friction in boundary and mixed lubrication regimes, whereas emulsifiers reduced friction in these regimes by enhancing fluid film formation. Under elastohydrodynamic conditions and with artificial saliva, friction was more influenced by the interaction between particle size and emulsifier level. Textural analysis showed that both parameters significantly influenced hardness, with saliva further softening the samples, especially those with higher emulsifier levels. Sensory evaluations indicated that emulsifiers enhanced flavor release and mouthfeel attributes, while smaller particles contributed to smoother texture and more balanced flavor perception. Consumer acceptance tests confirmed that samples with smaller particles and higher emulsifier levels received the highest scores in overall liking, taste, and texture. Instrumental parameters strongly correlated with key sensory attributes, with yield stress showing the highest positive associations with creaminess, smoothness, fat/milk flavor, and liking, while higher viscosity and friction were negatively linked to flavor release and mouthfeel. Instrumental hardness negatively correlated with cacao intensity and astringency, while saliva-induced softening was positively associated with sweetness and liking, highlighting the role of dynamic oral softening.