Engineering Problem Solving I 59:005, The University of Iowa
Guilt-Free Chocolate...
Chocolate Manufacturing
and
Food Processing
Engineering Problem Solving I 59:005, The University of Iowa
Learning Objectives
By the end of this lesson students will – be able to describe the industrial process for chocolate
manufacture from “bean to bar”
– be able to identify economic and political issues involved in the trade of cacao
– be able to identify major chocolate manufacturing companies
– be able to identify benefits of sustainable cocoa cultivation
– be able to list some Good Manufacturing Practices for food handling
Engineering Problem Solving I 59:005, The University of Iowa
Learning about Chocolate
History of Chocolate Economics of Chocolate Engineering of
Chocolate
EPSI: Chocolate Cookie Project
www.chocolateandcocoa.org
Engineering Problem Solving I 59:005, The University of Iowa
Chocolate Manufacturers Association
“CMA's mission is to serve as the voice of the American chocolate industry and through research, education and public information, works to ensure a continued supply of cocoa and increased consumption of high value and quality chocolate products for the American people.”
www.chocolateandcocoa.org
Engineering Problem Solving I 59:005, The University of Iowa
ADM Cocoa– http://www.admworld.com/
products/cocoa.htm Barry Callebaut USA, Inc.
– http://www.barry-callebaut.com/
Blommer Chocolate Company– http://www.blommer.com/
Guittard Chocolate Company– http://www.guittard.com/
Hershey Foods Corporation– http://www.hersheys.com
M&M/MARS– http://global.mms.com/us/index.jsp
Nestle Chocolate & Confections– http://www.nestle.com/
World's Finest Chocolate– http://www.worldsfinestchocolate.com/
Wilbur Chocolate, a Cargill Foods Company– http://www.wilburchocolate.com/
index.html
Engineering Problem Solving I 59:005, The University of Iowa
Chocolate world The cocoa plant is scientifically named Theobroma cacao.
– Theobroma -- Greek word: 'food of the gods'
– cacao -- from Aztec word: cacahuatl.
Toltecs, Mayas, and Aztecs first enjoyed the fruit of the divine cocoa tree.
Spain and Italy helped introduce the cocoa bean to the rest of the world.
“Today cocoa is an international trading commodity”
Barry Callebaut, USA Inc. 2002
Engineering Problem Solving I 59:005, The University of Iowa
History of Chocolate
1519 -- Conquistidor, Don Hernan Cortez took cocoa from Mexico to Spain
1606 -- Francesco Carletti brought cocoa from Central America to Italy
1825 -- Cocoa press invented in Holland by Van Houten
1828 -- Alkalization process invented
1875 -- First milk chocolate produced
www.chocolateandcocoa.org
Engineering Problem Solving I 59:005, The University of Iowa
Cocoa Producing Countries
Barry Callebaut, USA Inc. 2002
Near the equator, high T and high humidity
Engineering Problem Solving I 59:005, The University of Iowa
Cocoa producers
Amazon basin – 20% of world Cocoa is from Central and South
America Phillipines and West Indies
– 17th and 18th Centuries West Africa
– 19th Century– Ivory Coast & Nigeria
Engineering Problem Solving I 59:005, The University of Iowa
Chocolate Consumers
Barry Callebaut, USA Inc. 2002
Engineering Problem Solving I 59:005, The University of Iowa
From Crops to Commodity
Grow cocoa trees for 4 months Open and skin fruit Harvest beans Ferment on banana leaves
– microbes feed on sugar and pulp on beans– beans turn brown
Dried and turned for 14 days Sampled for Quality Shipped and traded on international market
Engineering Problem Solving I 59:005, The University of Iowa
Markets for Cocoa Beans
Open
Do not integrate chocolate in to their own products– Cargill
– ADM
– Barry Callebaut
Captive
Produce chocolate for their own products– Cadbury
– Nestle
– Kraft Jacobs Suchard
QuickTime™ and aTIFF (Uncompressed) decompressorare needed to see this picture.
Barry Callebaut, USA Inc. 2002
Engineering Problem Solving I 59:005, The University of Iowa
Economics of Cocoa
http://www.candyusa.org/CocoaTree/sustain.htm
Small Farms -- 90% of world cocoa on 5-10 acre farms
Market price impacts plant quality Challenges with pests and disease impact market.
Engineering Problem Solving I 59:005, The University of Iowa
Trading Cocoa
Supply and Outlook -- Ivory Coast produces the most cocoa. Weather issues during harvesting will increase the price of cocoa futures.– http://www.chocolateandcocoa.org/Supply/supplyindex.htm
Demand -- Most cocoa is consumed in the U.S. and Europe, but Asian countries are beginning to import cocoa.– http://www.chocolateandcocoa.org/Supply/
demand_prices.htm
Engineering Problem Solving I 59:005, The University of Iowa
Political Issues The IMF (International Monetary Fund) and the World
Bank, have attempted to help poor countries with international debts by altering the world cocoa market.
Recently, Ivory Coast opted for “liberalization” removing government controls on the cocoa market. A power struggle over control of the market ensued.
Issues of slavery, child slavery, and child labor in the Ivory Coast cocoa industries continue to worry chocolate manufacturers.
Engineering Problem Solving I 59:005, The University of Iowa
Dealing with Slavery...
“Persuaded by anti-slavery groups and the threat of U.S. legislation, chocolate manufacturers [in 2001] endorsed a four-year plan to identify and address instances of abusive child labor in cocoa-growing countries in West Africa.
They signed a protocol, which sets a series of deadlines through 2005 to lay groundwork for monitoring and remedying abusive forms of child labor in those countries.”
Engineering Problem Solving I 59:005, The University of Iowa
Chocolate Manufacturing
and
Food Processing
Guilt-Free Chocolate... From Bean to Bar
Engineering Problem Solving I 59:005, The University of Iowa
“Bean to Bar” Process Clean and inspect beans --
– de-dusted
– de-stoned
– passed through metal detector
Roast beans – sterilizes and adds aroma
Break beans and grind “nibs”– separate nibs and shells
– sizing and milling
Prepare cocoa mass– Squeeze out cocoa butter
Fine Rolling– cocoa mass + sugar = dark chocolate
batter
– cocoa mass + sugar + milk= milk chocolate batter
Conching– Kneading machine
– removes water and acid
– add fat and cocoa butter
– pump to storage tanks
Tempering– heat treatment
– brings cocoa butter to stable crystal form
Engineering Problem Solving I 59:005, The University of Iowa
Watch Chocolate Processing...
Note Major Pieces of Equipment Note Safety Issues in the Facilities
What household items, analogous to the processing equipment, would enable you to make your own personal chocolate?
http://www.candyusa.org/CocoaTree/index.htm
Engineering Problem Solving I 59:005, The University of Iowa
Brainstorm
List food-handling considerations in your home?
How might these principles be implemented on an industrial scale?
Engineering Problem Solving I 59:005, The University of Iowa http://www.gmp1st.com/gmp.htm
GMP -- regulations developed by the FDA under the authority of the Federal Food, Drug, and Cosmetic Act
Require that “manufacturers, processors, and packagers of drugs, medical devices, some food, and blood take proactive steps to ensure that their products are safe, pure, and effective.”
GMP regulations address issues including recordkeeping, personnel qualifications, sanitation, cleanliness, equipment verification, process validation, and complaint handling.
Good Manufacturing Practices
Engineering Problem Solving I 59:005, The University of Iowa
Elements of GMP
“The plant management shall take all reasonable measures and precautions to ensure the following:”– Disease Control– Cleanliness– Education and Training– Supervision
Engineering Problem Solving I 59:005, The University of Iowa
GMP -- Cleanliness
“Wearing outer garments that protect against the contamination of food, food-contact surfaces, or food packaging materials.”
“Maintaining adequate personal cleanliness.” “Washing hands thoroughly (and sanitizing if necessary)” “Removing all unsecured jewelry and other objects that might
fall into food” “Maintaining gloves, if they are used in food handling, in an
intact, clean, and sanitary condition” “Wearing, where appropriate, in an effective manner, hair nets,
headbands, caps, beard covers, or other effective hair restraints”
Engineering Problem Solving I 59:005, The University of Iowa
GMP -- Cleanliness
“Storing clothing or other personal belongings in areas other than where food is exposed or where equipment or utensils are washed.”
“Confining the following to areas other than where food may be exposed or where equipment or utensils are washed: eating food, chewing gum, drinking beverages, or using tobacco.”
“Taking any other necessary precautions to protect against contamination of food, with microorganisms or foreign substances including, but not limited to, perspiration, hair, cosmetics, tobacco, chemicals, and medicines applied to the skin.”
Engineering Problem Solving I 59:005, The University of Iowa
Coating Cookies with Chocolate
EPSI Team Project
http://www.wilburchocolate.com/docs/applications/bakery/chocolate_coatings.html
Engineering Problem Solving I 59:005, The University of Iowa
EPSI -- Cookie Coating Project
Coat cookies with chocolate. Estimate average and standard deviation of cookie
mass, before and after coating. Estimate average and standard deviation of the
coating thickness. Calculate nutritional value of the new cookie
product, including an ingredient list. Write a report of your project activities. Present your project results in class.
Engineering Problem Solving I 59:005, The University of Iowa
Available equipment and supplies
Cookies, chocolate chips, chocolate almond bark
Bowls, trays, wax paper, and kitchen utensils
Microwaves Kitchen scales and calipers Refrigerator
Engineering Problem Solving I 59:005, The University of Iowa
Project Assignments
Project 2: Chocolate-Coated Cookies
Progress Report (team)
Oct. 14 (email by 5 pm)
10
Written Report (team)
Oct. 21 (class) 50
Teamwork (ind) Oct. 21 (class) 20
Presentation (team)
Nov. TBA (in-class)
25