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???

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