Compounds Training - Asia_1

Compounds Training

CONFIDENTIAL. This document contains trade secret information. Disclosure, use or reproduction outside Cargill and inside Cargill, to or by those employees who do not have

a need to know is prohibited except as authorized by Cargill In writing. (Copyright Cargill, Incorporated 2006. All rights reserved.)

Compounds Training

Technical Services Team Cargill Asia

Carlos A. Veoso

November / 2011

Compounds Training

Agenda

Introduction

Raw Materials

Chocolate and Compounds Composition

Manufacturing Process

Applications

Defects

Compounds Training

Whats the difference between Chocolate and Compound?

Depends on the local legislation

Chocolate must contain a minimum of cocoa solids (cocoa butter, cocoa liquor, cocoa powder)

Fat used, when permitted, is CBE restricted to some countries

Specific regulations for milk chocolate / white chocolate

In Compounds cocoa fat is substituted by other vegetable fats

In general there are no restricted regulations for compounds

Compounds Training

Chocolate

confectionery

Chocolate

confectionery DessertsDesserts Ice creamIce cream

BakeryBakery Coated barsCoated bars CandiesCandies

Where Chocolate has been used?

Compounds Training

Where Compound has been used?

Chocolate

confectionery

Chocolate

confectionery DessertsDesserts Ice creamIce cream

BakeryBakery Coated barsCoated bars CandiesCandies

Compounds Training

Agenda

Introduction

Raw Materials



Applications

Defects

Compounds Training

Sugar

Cocoa derivatives

Milk derivatives

Oils and Fats

Emulsifiers

Flavors

Others

Raw Materials

Compounds Training

Sugar

Crystal sugar

- Sucrose -

Compounds Training

Cocoa Derivatives

Three ingredients come from the cocoa:

Cocoa Butter (100% fat)

Cocoa liquor (52 - 54% fat)

Cocoa powder (10 - 12% fat)

Compounds Training

Obtained by milling of the cocoa nibs after roasted

It gives the characteristic bitter taste of the chocolate

Dark brown color

Contains 52 54% of fat

Natural liquor (pH 5,8)

Processed with alkali

Cocoa liquor (Cocoa Mass)

Compounds Training

Hard at room temperature

Narrow melting range, between 32 and 34oC

Excellent melting in the mouth

No wax residues

Good taste

Resistant to oxidation

Natural or Deodorized

Cocoa Butter

Compounds Training

Obtained by the milling of the cocoa cake

Its the defatted fraction of the cocoa (10-12% fat)

Cocoa Powder

Natural powder (pH 5,8 6,0)

Alkalized powder (pH 7,0 7,2)

Red powder (pH > 7,4)

Compounds Training

Color and taste Development

5 5,5 6 6,5 7 7,5 8 8,5

Color

Darker and

Reddish

Brown

Clearer and

Yellowish

Brown

Compounds Training

5 5,5 6 6,5 7 7,5 8 8,5

Taste

Balanced and Strong

Astringent and Bitter

Smooth and Alkalized

Poor

Good

Color and taste Development

Compounds Training

Cocoa Butter Alternatives

CBS (Cocoa Butter Substitutes)

CBR (Cocoa Butter Replacers)

CBE (Cocoa Butter Equivalents)

Compounds Training

CBS

Lauric fats (palm kernel, coconut, babassu)

Hydrogenated, Fractionated, Interesterified

They are incompatible with Cocoa Butter

Compounds Training

CBR

Non lauric fats (palm, soya, cotton seed, rapeseed)

Hydrogenated, Fractionated, Interesterified

They are partially compatible with Cocoa Butter

Compounds Training

CBE

Chemically similar to the Cocoa Butter

From exotic fats (illipe, kokum, shea) and palm

Fractionated; some are enzymatic interesterified

Totally compatible with Cocoa Butter

Used to reduce cost in chocolates

Compounds Training

Alternative fats - resume

Characteristic Cocoa Butter CBS CBR CBE

Source Non lauric Lauric Non lauric Non lauric

Raw Material CocoaPalm kernel

Babassu;

Coconut

Palm; Soya;

Cotton seed ...

Palm; Shea;

Illipe; Kokum ...

Conversion process -

Hidrogenation

Interesterification

Fraccionation

Hidrogenation

Interesterification

Fraccionation

Fraccionation

Intersterification

Compatibility (*) - max. 5% 15 - 20% 100%

Require tempering Yes No No Yes

Contraction Excellent Excellent Regular - Good Excellent

Gloss ++ +++ + or ++ ++

Cost ++++ ++ + to +++ +++ to ++++

(*) Compatibity with cocoa butter (% on total fat)

Compounds Training

Add nutritional value

Excellent sensory properties

Milk fat gives creamier texture

Best seller worldwide Milk Chocolate

Milk Derivatives

Compounds Training

Whole milk powder (26% fat) Skimmed milk powder (1% fat) De-mineralized milk whey (

Compounds Training

Lecithin

Polyglycerol Polyricinoleate (PGPR)

Emulsifiers

Effect on the Viscosity and on the Yield Value

Compounds Training

23

Compounds Training

Nuts (48-65% fat)

Good taste profile

Give softer texture

Malt extract Flavors (Vanillin, ethyl vanillin, etc.) Seasonings, coffee Salt

Taste modifiers

Other Raw Materials

Compounds Training

Agenda

Introduction

Raw Materials



Applications

Defects

Compounds Training

Dark Chocolate

Milk Chocolate

White Chocolate

Cocoa Liquor Cocoa Butter + + Sugar Milk + =

Cocoa Liquor Cocoa Butter + + Sugar =

Cocoa Butter + Sugar Milk + =

Chocolate Composition

Compounds Training

Cocoa Butter Licor de Cacao

Licor de Cacao

Compound Composition

Dark Compound

Milk Compound

White

Compound

Cocoa Powder + + Sugar Milk +

=

Cocoa Powder

Vegetable Fat

+ + Sugar =

+ Sugar Milk + =

Cocoa Butter

Cocoa Butter

Vegetable Fat

Vegetable Fat

Compounds Training

Chocolate: Basic Composition

Solid Phase

65-72%

Sugar

Non fat Cocoa solids

Non fat Milk solids

Ingredient

Sugar

Cocoa Liquor

Cocoa Butter

Milk

Vegetable Fat

Liquid Phase

28-35%

Cocoa Fat

Cocoa Fat

Milk Fat

Vegetable Fat

Compounds Training

Cocoa Fat Cocoa Butter Cocoa Fat Cocoa Butter

Solid Phase

65-72%

Acar


Slidos deseng. do leite

Ingrediente

Acar

Cocoa Liquor

Leite

Gordura equivalente

Liquid Phase

28-35%

Cocoa Fat

Gordura de Leite

Alternative Fat

Compound: Basic Composition

Sugar

Non fat Milk solids

Sugar

Milk

Vegetable Fat

Ingredient Solid Phase

50-70% Liquid Phase

30-50%

Non fat Cocoa solids Cocoa Powder Cocoa Fat

Milk Fat

Vegetable Fat

Compounds Training

Esquematic Phases Representation

Sugar


Non fat Milk solids

Continuos phase: FATFAT

Interface: EMULSIFIEREMULSIFIER

Compounds Training

Chocolate: Basic Recipes

Ingredient Milk Chocolate White Chocolate Dark Chocolate

Sugar 40% - 50% 40% - 55% 40% - 50%

Cocoa Liquor 9% - 14% 0% 20% - 40%

Cocoa Butter 13% - 22% 20% - 29% 0% - 18%

Milk Solids (include fat) 10% - 20% 16% - 28% 0% - 3%

Milk Fat 1,5% - 6% 3,5% - 6% 0% - 3%

Equivalent Fat 0% - 10% 0% - 10% 0% - 10%

Soya Lecithin 0,25% - 0,50% 0,25% - 0,50% 0,25% - 0,50%

PGPR 0,00% - 0,25% 0,00% - 0,25% 0,00% - 0,25%

Compounds Training

Compound: Basic Recipes

with CBS with CBR with CBS with CBR

Sugar 45% - 65% 45% - 65% 45% - 60% 45% - 60%

Cocoa solids 5% - 15% 5% - 20% 0% 0%

Milk solids 0% - 20% 0% - 20% 10% - 28% 10% - 28%

Cocoa fat 0,5% - 1,5% 0,5% - 6,0% 0% 0,0 - 6,0%

Vegetable fat 28% - 32% 24% - 32% 28% - 33% 24% - 33%

Milk fat 0,0% - 1,0% 0,0% - 4,5% 0,0% - 1,5% 0,0% - 6,0%

Cocoa fat + milk fat mx. 1,5% mx. 6,0% mx. 1,5% mx. 6,0%

Soya lecithin 0,25% - 0,45% 0,25% - 0,45% 0,25% - 0,45% 0,25% - 0,45%

PGPR 0,00% - 0,20% 0,00% - 0,20% 0,00% - 0,20% 0,00% - 0,20%

Flavors 0,02% - 0,20% 0,02% - 0,20% 0,02% - 0,20% 0,02% - 0,20%

Compound (Milk and Dark) White CompoundIngredient

Compounds Training

SensorySensory

Taste

Flavor

Color

Melting

Gloss

Texture (snap)

PhysicalPhysical-Chemical

Viscosity and Yield Value

Fineness

Moisture

MicrobiologicalMicrobiological

According to standards

Pathogens absence

Desired characteristics

Compounds Training

Agenda

Introduction

Raw Materials



Applications

Defects

Compounds Training

Chocolate Manufacturing Process

Ingredients scaling and mixing

Refining

Conching

Tempering and Crystallization

Molding or Enrobing

Packaging

Compounds Training

Chocolate Manufacturing Process

Ingredients scaling and mixing

Refining

Conching

Tempering and Crystallization

Molding or Enrobing

Packaging

Chocolate mass manufacturing

Shaping and Finishing

Compounds Training

Refining

Particle size reduction

Final fineness between 18m and 40m

Conventional process: 5-rolls refiner

Ball mill

Universal conches (type McIntyre)

Compounds Training

5-rolls refiner

1

2

3

4

5

Fe

ed

ing

Conventional process

Compounds Training

Particle reduction

Continuous or batch

Vertical or horizontal

Ball mill

Compounds Training

Mixing

Physical and Chemical transformations

Aroma development

Shearing

Drying

Sensory development

Flow characteristics improvement

Conching

In general is not used for Compounds

Compounds Training

Temperature 60 65oC in Milk Chocolate

70 85oC in Chocolates without milk

Time 6 - 12 hours

Conching

Compounds Training

Conching dry phase

Compounds Training

Conching plastic phase

Compounds Training

Conching liquid phase

Compounds Training

Flow characteristics of Chocolate and

Compounds - Rheology

Viscosity:

Resistance to movement when the chocolate flows

Yield Value:

Minimum force to flow (to start the movement)

Compounds Training

46

Compounds Training

47

Compounds Training

48

Compounds Training

49

Compounds Training

50

Compounds Training

Chocolate rheology

VariableEffect on

Viscosity

Effect on Yield

Value

Higher fat content Reduce Reduce

Higher particle size Reduce Reduce much

Lecithin addition up to 0.6% Reduce much Reduce

PGPR addition No interference Reduce much

Moisture Increase much Increase much

Conching time Reduce a little Reduce

Shear or vibration No interference Reduce

Compounds Training

Chocolate tempering

Pre-crystallization

Direct cocoa butter crystallization to favor stable crystals formation

Compounds dont need tempering

Compounds Training

Cocoa butter polymorfism

16oC - 18oC

21oC - 24oC

27oC - 29oC

30oC - 34oC

Crystal Melting point Stability Size

incre

ase

red

uce

Compounds Training

Chocolate tempering curve

15

20

25

30

35

40

45

0 2 4 6 8TE

MP

ER

AT

UR

E (

C)

RETENTION TIME (min)

Compounds Training

Chocolate Tempering

At begining the fat must be completely melted no crystals (45C)

4% de cristais obtained

Micro crystals formation

Instable crystals melting

Cooling with

agitation

Compounds Training

Thermal resistance

Gloss

Right texture (snap)

Right contraction (demolding)

Shorter cooling time

Chocolate Tempering

Compounds Training

Chocolate and Compounds Crystallization

Fat crystallization

Cooling with air circulation

Temperature between 7 and 14C

Chocolate contraction Demold

Compounds Training

Chocolate and Compound molding - bars

Mold temperature: 1 to 2C below product temperature

Product temperature:

Chocolates: 29-31C

Compounds: 40-45C

Cooling temperature:

Chocolates: 10-14C

Compounds: 7-10C

Cooling time: 40 - 70 minutes (depending on the product size and shape)

Compounds Training 5

9

Chocolate and Compound molding - bars

1. Empty mold

3. Partial contraction 4. Total contraction

2. No contraction

Compounds Training

0

5

10

15

20

0 5 10 15 20 25 30

Dew

poin

t (C)

Dry bulb temperature (C)

Hygrometric chart

13

Compounds Training

Compounds Crystallization

No need tempering

Crystallize in the form

Higher depositing temperature (higher than 40C)

Fast cooling (7-10C)

Several small crystals

CBS

and

CBR

CBE Must be treated as chocolate

Compounds Training

Chocolate and Compound Storage

Chocolates: ideal 18 - 23C

Tolerable up to 26C

Compounds: ideal 21 - 26C

Tolerable up to 34C

Solid form:

Compounds Training

Chocolate and Compound storage

Tanks with slow agitation

Jacketed at 45oC

Some compounds require different temperatures (higher or lower)

depending on the melting point of the fat

Liquid form:

Compounds Training

Agenda

Introduction

Raw Materials



Applications

Defects

Compounds Training

Molding: chocolate/compound deposit into molds

Coating (enrobing): filling coated with chocolate/compound

Rasps: chocolate/compound bar rasped to decoration

Panning: centers recovered with chocolate/compound

Chocolate and Compounds Application Processes

Compounds Training

Molded products

Depositor

Compounds Training

Enrobed products

Enrober

Compounds Training

Panned products

Belt pan

Automatic pan

Compounds Training

Sealing (usually with Arabic gum and sugar)

Protects against moisture and oils migration

Reduces stickiness and bunches

Facilitates thickening process

Thickening (several layers 60-80% of the product)

Melted chocolate (not tempered) or compound

Cool and dry air blowing

Polishing

Panning process

Compounds Training

Chocolate rasps

Compounds Training

Cocoa Butter

Fractionated vegetable fats

Hydrogenated vegetable fats

Fat type used is determinant for the cost and product applicability

Fat represents 30% 35% of the product (until 50 55% in ice cream coatings)

Compounds Training

Hig

her

cost

Bette

r m

eltin

g in the m

outh

Bette

r to

rasps

Mold

ing

Bette

r th

erm

al re

sis

tance

Need T

em

pein

g

COCOA BUTTER

FRACTIONATED FATS

HYDROGENATED FATS

High standard products

Popular products

Compounds Training

Main differences: Chocolate vs Compounds

7

3

Parameter CHOCOLATE COMPOUND

COMPOSITION Fat base Cocoa Butter Vegetable Fat

PROCESS

Conching important not important

Tempering necessary no need

Temperature storage 45oC 45 - 50oC

Temperature use 29 - 31oC 40 - 45oC

Cooling temperature 10 - 14oC 7 - 10oC

COST Process and ingredients High Low

STORAGE

Temperature up to 26oC up to 34oC

Aging less critical more critical

Blooming sensitive to

temperature variation sensitive to fat

incompatibility

APPLICATIONS Flexibility Low High

Compounds Training

Agenda

Introduction

Raw Materials



Applications

Defects

Compounds Training

Moisture, water, steam

Heat

Odors

Chocolate and Compounds enemies

Compounds Training

Fat Bloom

Product suffered heat

Wrong tempering (chocolates)

Wrong crystallization

Fat incompatibility

White spots caused by cocoa butter or fat crystallization on the surface

Main causes:

Compounds Training

Sugar Bloom

Water condensation in the cooling tunnel output

Water condensation by exposition in wet environment

White spots caused by sugar crystallization on the surface

Main causes:

Compounds Training

Odors sorption

Storage or transport in wrong environment

Interaction with package material

Taste and odor modification by odor sorption from the environment

Main causes:

Compounds Training

Fat rancidity

Oxidation

Unsaturated fat acids oxidation

Hydrolisis

Free fat acid formation by hydrolysis

Compounds Training

Oxidation

Needs oxygen and is accelerated by

Temperature

Light

Metallic ions

Related to double bond attack Saturated and hydrogenated are more stables

Compounds Training

Fat hydrolysis

Short chain fat acids are more critical

Milk Fat: rancid taste

Lauric fats: soap taste

Need moisture and lipase

Compounds Training

Darkening

Occurs sharply in the white chocolate and compound and is accelerated

by the light incidence

Packaging with light barrier

Compounds Training

Melting point reduction

Inappropriate crystallization

Phases separation

Fat Bloom

Fats incompatibility and Eutectic Effect

Mix of different fats Melting point reduction of

the mixture

Compounds Training

0

10

20

30

40

50

60

70

80

90

0 10 20 30 40 50 60 70 80 90 100

SF

C (

%)

% coconut oil

Eutectic diagram: Cocoa butter - coconut oil

a 10,0C

a 21,1C

a 26,7C

a 33,3C

Compounds Training 8

5

Interaction Biscuit Coating

In warm conditions:

Fat from Biscuit migrates to Coating

resulting Fat Bloom

Interaction Filling Coating

In warm conditions:

Fat from Filling migrates to Coating resulting

Fat Bloom

- Incompatibility of fats: lauric fat cocoa butter - Liquid fraction (oil or fat) migrating to the surface


Compounds Training

Chocolates and Compounds are in general incompatibles

Lauric fats x Chocolate: very critical

Compounds x Cocoa butter: very critical

Lauric compounds x non lauric: less critical Ice cream coatings: no critical


Compounds Training

Thank you very much

[email protected]

Documents

Compounds Training - Asia_1