chocolate process
TRANSCRIPT
Chocolate Manufacture
CHOCOLATE COMPANY
Key elements of chocolate for the confectioner
Flavor
Color
Particle size (fineness)
Viscosity
Fat content
Melt properties (cocoa butter hardness)
Chocolate Standards–Essentials
Only cocoa butter and butter oil permitted fatsChocolate flavor from chocolate liquor onlyOnly “nutritive carbohydrate sweeteners” permittedNo flavors simulating chocolate or dairy permitted
Milk Chocolate Standard
21 CFR § 163.130
Chocolate liquor 10% minimum
(no maximum)
Milk - 12% minimum
Milk Fat - 3.39% minimum
Dark Chocolate Standard 21 CFR
§163.123 Sweet Dark Chocolate
Chocolate liquor 15 min 35 max
Milk - 12% maximum
Semi-sweet / Bittersweet ChocolateChocolate liquor 35% minimum
Milk - 12% maximum
No maximum liquor level!
White Chocolate Standard
21 CFR §163.124
Only fats permitted are cocoa butter and milk
fat
Cocao Fat – 20% Minimum
Milk – 14% Minimum (Whey 5% Max)
Milk fat – 3.5% Minimum
No flavorings that mimic flavor of chocolate, milk, or butter
Chocolate
Depositing or Molding Liquid Holding
Mixing Ingredients
Prerefining
5-Roll Refining
Conching
Standardizing
Discs or Drops 10 lb. bars Tankers
CHOCOLATE MANUFACTUR
E
Confectionery Coatings
Current CFR Typically NOT Used
Referred to as “Confectionery Coating”
Cannot be labeled as “Chocolate”
Fat other than Cocoa butter usedLauric, Nonlauric vegetable fats
Flavorings not limited
Sugar free chocolate flavored ctgs.
CONFECTIONERY COATING MANUFACTURING
C O A T IN G M A N U F A C T U R E
S T A N D A R D IZ IN G
B A L L M ILL IN G
S T A N D A R D IZ IN G
5 R O L L R E F IN IN G
P R E R E F IN IN G
M IX IN G -W E T
S T A N D A R D IZ IN G
M IX E R /K N E A D E R
D R Y G R IN D IN G
M IX IN G -D R Y
Sensory of Chocolate & Confectionery Coating
Mixing, Refining, and
Conching
Batch Mixing
Mix raw
materials and
a portion of the
fat
R&D Batch Mixing
Refining Line
Manufacture of Chocolate Masses
Ingredient bins
Mixing / kneading
1
2
Pre-refining
Final refining
3
4
Conching
Electric plant control
5
6
Chocolate Paste (Before Refining)
Chocolate Refiner Line
5 Roll Refiner
140-200 µm
1 : 1 0
W 5
W 4
W 3
W 2
W 1
70-100 µm
20 µm
1 : 5
70-100 µm
20 µm
140-200 µm
W 2W 1
VorwalzwerkPre-Refiner
PrébroyeusePrerefinadora
SZAESZANSZWA
FünfwalzwerkFive-Roll RefinerBroyeuse à 5 cyl.
Refinadora de 5 cil.
SFLASFLESFLN
VorwalzfeinheitPre-refined particle sizeFinesse de prébroyageFinura del prerefinado
DifferentialGear RatioDifférentielDiferencialW2 : W5
Relationship of Pre-Refining and Final Refining
Mechanical Size Reduction in Chocolate
Pre refiner conditions mass
Finished refining completes particle reduction
Rolls slightly crownedPressure exerted
Thin film forms on rolls
Speed of rolls Increase bottom to top
Creates shearing action
Gap adjustment based on final fineness
Envelope particles with fat
Refiner Flake
Refiner flake traveling to Conche
Micrometer
AACT Micrometer Fineness Method
Rotating micrometer must be used50 / 50 Oil and chocolate well mixedMicrometer cleaned and zeroedTemperature sensitiveConsistent slip or ratchet clutch between technicians and micrometersMicrometer in good repair–free movement, not “catching”Put away clean with the anvils slightly open
Particle AnalyzerScattered Light
Measure scatterAmount
Direction
Calculates Size Distribution
Fast QC Check
Sensory of Particle Size
Taste and evaluate each piece
For : Sweetness
Mouth feel
Melt
Flavor Release
Why Different Particle Size?
Boxed Chocolates – 10 –20 microns
Chocolate Chips – 15-35 microns
Truffles – 10-15 microns
Inclusions - 15- 45 microns
Solid Pieces – 10-25 microns
Novelty items – 15-45 microns
Conching
Flavor DevelopmentEnergy into Mass (Shearing & Heat)
Conching Time
Conching Temperature
Rounding Particles (Texture)
Volatile Removal
DÜ C -G
AB
Y
IsolationsschichtInsulation layerCouche d'isolationCapa del aislamiento
DoppelmantelWater jacketEnveloppe doubleCamisa doble
X
X Y
A
RechtslaufClockwise rotationMarche à droiteGiro a la derecha
B
LinkslaufAnti-clockwise rotationMarche à gaucheGiro a la izquierda
Doppel-Überschlag-Conche Double-Overthrow Conche Conche à double effet Concha de doble volteo
Frise DUC-6 Conche
Refiner Flake Feeding Conche
High Shear Conches – East Greenville
Conching
Pilot Frisse Conche
Sensory of ConchingFocus on:
Degree of Chocolate
Sweetness
Caramel
Dairy
Viscosity–What is it and how is it measured
Viscosity:Resistance to flow
(“thickness” / “thinness”)
Rheology:The science of the deformation
and flow of fluids
Viscosity Check
Viscosity Ranges for Chocolate Use
Receiving Chocolate
Verify that–
Trailer is clean and free of odors
Product is what it is supposed to be
Product temper is good
Product specifications are met
Satisfactory temperature control during shipment
Cases are not damaged or torn
Above all just taste it– make sure it is OK
Chocolate Storage Problems–Before Use
Pick up of off odors from the storage areaOther food products (mints, flavor ingredients, spices, onions, etc..)
Other products (maintenance oils, cleaning supplies, etc..)
Air conditioning systems (dirty filters or cooling coils, plugged drain pans–also microbiological issue)
Moisture pickupFrom high RH storage, thickens chocolate
Viscosity impacts:
Confectioner’s handling of chocolateCoverage percent
Dipping Thickness & uniformityEnrobing Side coatingMolding Feet / tails
Air bubblesDecoration
PumpingTank agitation
Air Bubble Release in Agitated Kettle
Feet or Slump on Sides of Finished Goods
Drop Depositing
Requires High Yield
Value
Chocolate pumping after Conching
Liquid Chocolate Loading
Liquid Chocolate Ready to Deliver
10 lb Chocolate Bar Depositing
10 lb Bar Packaging
Warehousing Chocolate Products
Thank You - Questions???
Why am I in Here?