Modelling the Cooling Kinetics of Chocolate Coatings with

Respect to Final Product Quality

Knut Franke
(;crman lnstitutc of Food Technology. Prof.-von-Klitzing-Str. 7, 4OhlO Quakenbrueck.
Germany

(Received 1.3October 1097: accepted 20 April 1998)

ABSTRACT

Cooling of’ chocolate coated products requires cooling tunnels with optimal
settings according to product and chocolate properties to get the desired qua&
with respect to suface gloss and hardness of coating. The author proposes CI
modrl for the calculation of the bulk crystallization and temperature variation
within ‘the coating during cooling. The model is based on one-dimmsional,
l(nsteadv-state heat transfer accounting -for internal heat generation h!
c~rystall/zation. The latter is assumed to be a function both of current
temperature and non-crystallized material. Simulations of cooling of coated
cookies under different cooling conditions in a two-step process using the model
.show possibilities for optimizing the process with respect to expected suface
gloss and hardness. 0 1998 Elsevier Science Limited. All rights reserved

NOTATION
Thermal diffusity (m2/s)
Specific heat capacity (kJ/kg K)
Dependence of crystallization rate on the heat of crystallization being
already released (kJ/kg s)
Dependence of crystallization rate on the temperature (-)
Value for the initial rate of crystallization (-)
Dependence of the rate of crystallization from undercooling (l/K)
Final slope of the function f,(Qm)
Initial slope of the function f,(&)
Specific heat of crystallization per time unit (kJ/kg*s)
Overall specific heat of crystallization generated in the chocolate during
cooling (kJ/kg)
Specific heat of crystallization per time unit which has already been
released during crystallization (kJ/kg)
371
372 K. Franke

Qmax Dependence of the rate of crystallization from the amount of non-crystal-

lized material available (kJ/kg)
t Time (s)
T Temperature (“C)
Tcrist Initial temperature of crystallization (“C)
X Location (m)
A Thermal conductivity (W/m*K)
P Density (kg/m3)

INTRODUCTION

Confectionery centres and biscuits are often enrobed with a thin chocolate coating.
The process includes the pre-crystallization of the chocolate mass, enrobing and
finally solidification of the coating on the centre within a cooling tunnel (Fig. 1).

Chocolate mass

I Pre-crystallization I

I i- centfe

Enrobing I

Fig. 1. Enrobing process with chocolate mass.

 Modelling the cooling kinetics of chocolate coatings 373

The final quality of the chocolate coating is generally evaluated according to

- gloss of the coating,
- degree of solidification (fingerprint) and
- coat thickness.
These quality parameters are influenced both by the correct pre-crystallization
and by the following cooling procedure. Therefore, one can get a poor coating
because of unsuitable cooling conditions although a well pre-crystallized chocolate
mass is used for enrobing. Although pre-crystallization and enrobing have often
been investigated by different authors, there is only little information available
about the optimum cooling kinetics for reaching a high-quality coating under dif-
ferent conditions.
State of the art continuous-working cooling tunnels for coated products contain
different zones through which the product passes in turn. Figure 2 shows a schema-
tic structure of a zone. Within a zone, separate control is available for the
temperatures of air, bottom and radiant surfaces and the air velocity, respectively.
This permits an individual control of cooling conditions for specific product
demands and properties.
The long-term experience of chocolate manufacturers shows that an initial slow or
gentle cooling gives a better gloss than intensive cooling (Muntener, 1988; Gopel,
1993; Ziegleder, 1995). That is, the crystallization rate within the chocolate coating
should be low. On the other hand, a slow cooling requires longer cooling time and
longer cooling tunnels to get a product with the solidification needed for subsequent
packaging. An coating insufficiently solidified has a soft surface that can easily be
scratched during packaging and can lead to quality failures of the final product.

4
I
5

upper cover of the cooling tunnel

radiation plate (cow ter plate for radiation)

enrobed article

conveyer

bottom cooling
Fig. 2. Schematic structure of a cooling tunnel section.
374 K. Franke

To realize both adequate gentle cooling for the desired gloss and a short cooling
time, the cooling tunnels are operated in two or more steps. In the first step, cooling
is carried out without forced convection (air velocity is zero), so a relatively slow
cooling and bulk crystallization takes place. In the second step cooling is intensified
by forced convection to get the desired solidification of the coating surface. For the
same chocolate mass, the correct setting of the cooling times for each step and the
suitable cooling conditions (temperatures and velocities) within the steps depend on
the coating thickness and the centre properties (for example size, temperature, heat
capacity). This decision is commonly made on the basis of experiences and, if
necessary, trial-and-error tests in the production line, causing high costs for the
manufacturer.
The author proposes a model of the process, which makes it possible to simulate
the temperature course and also the bulk crystallization rate within the chocolate
coating during cooling depending on cooling conditions and product properties.
There is little information available about crystallization kinetics of pre-crystal-
lized chocolate or cocoa butter under practical conditions. Brosio et al. (1980)
published results of melting and crystallization of cocoa butter with cooling tem-
peratures of 7°C and -18°C. Ziegleder (1990) presented results of kinetic
experiments with non pre-crystallized cocoa butter of different origins. In addition,
Ziegleder (1995) carried out cooling experiments with pre-crystallized plain choc-
olate in a DSC and published plots of the release of crystallization heat under
isothermal conditions at different temperatures.
There are some publications describing the modelling of cooling processes of
foods taking into consideration latent heat within the model equations. Schwartz-
berg (1977) proposed an effective temperature-dependent heat capacity containing
the ‘normal’ heat capacity and the associated latent heat at the respective tempera-
ture. This effective heat capacity includes the value of latent heat, a freezing point
depression and other material constants. Such an approach was also used by Cleland
and Earle (1984) Reinick and Schwartzberg (1986) and Saad and Scott (1996)
respectively.
Chau and Gaffney (1990) calculated the heat and mass transfer of spherical foods
taking into consideration an internal heat generation by respiration. The respiration
rate and therefore the heat generation was assumed to be constant.
Lin (1994) published a model for the freezing process of alginate gels with the
assumption of a sharp freezing (crystallization) front within the product. The tem-
perature of the crystallizing zone is assumed to remain constant until crystallization
is completed in this zone.

APPROACH FOR MODELLING THE BULK CRYSTALLIZATION OF

CHOCOLATE

The modelling is based on the numerical calculation of the one-dimensional,

unsteady-state temperature distribution and crystallization rate within the chocolate
coating depending on cooling time and localization (chocolate layer). The modelling
approach of the cooling behaviour of the chocolate coating follows the simplified
layout showed in Fig. 3.
The enrobed centre and the chocolate coating are assumed as even, infinite slabs.
This one-dimensional approach is suitable for describing the cooling behaviour of
 Modelling the cooling kinetics of chocolate coatings 37.5

1 cooling tunnel side

2 chocolate coating
3 enrobed cents
4 conveyor and bottom cooling
Fig. 3. Layout for the modelling approach of chocolate coating cooling.

very flat enrobed centres, like cookies, and allows model calculations with a limited
numerical capacity.
The description of the one-dimensional, unsteady-state temperature distribution
depending on localization (x) and time (t) gives the following differential eqn (1)
with consideration of a heat source by crystallization:

(1)

temperature heat conduction heat source

change per
time step
The following initial and boundary conditions are used to solve eqn (1).

Initial condition

The coating is assumed to have a uniform temperature of pre-crystallized chocolate

mass. Generally, this temperature is in the range between 30 and 32°C depending on
the sort of chocolate. The initial centre temperature is assumed to be also uniform
but different from that of the coating. This temperature is in the range between 18
and 26°C for parameter estimations and simulation examples.
376 K. Franke

Boundary conditions

The heat transfer coefficients on the coating-air interface are calculated according
to the equations given in Verein Deutscher Ingenieure (1988) both for natural and
forced convection. These calculations take into consideration the actual air tempera-
ture and velocity and in the case of natural convection the initial temperature of the
chocolate for determination of AT. The calculation of the heat flux at the coating-
centre interface is based on an energy balance. The bottom of the centre is assumed
to be on the cooled conveyor. Therefore, the temperature of the centre bottom is
set to that of the conveyor.
The dependence of the internal heat conductivity L(T) of chocolate on tempera-
ture is calculated using published measured values in Franke et al. (1994a, 1994b).
The specific enthalpy of crystallization per time unit being just released during
bulk crystallization is expressed by 4,(T, Q,,,). High values of &(T, Qm) mean a
high crystallization rate because there is a high heat output per time unit by
crystallizing cocoa butter and vice versa low values represent a low crystallization
rate.
Because of the relatively low crystallization rate of cocoa butter during cooling
compared with that of water, it can be expected that no sharp crystallization front
occurs within the coating. Thus, decreases of temperature and crystallization occur
simultaneously during cooling (Fig. 6). Therefore, another approach for the descrip-
tion of crystallization behaviour is necessary.
The modelling approach of chocolate crystallization during cooling uses the fol-
lowing assumptions:
- the chocolate is well pre-crystallized, so that a sufficient content of nuclei in the
stable form exists and no nucleation is necessary
- the cooling conditions enable a growth of these nuclei and no additional
nucleation of unstable forms occurs
These assumptions are generally met in cooling tunnels under normal conditions.
The basic modelling approach is that the released heat of crystallization depends
both on the actual temperature T =f(t, x) in the chocolate layer and the heat of
crystallization Qm that has been released up to the current time (Franke et al.,
1994a, 1994b).
Two fundamental mathematical conditions result from these assumptions.
1. As long as the temperature of the chocolate mass is higher than the start
temperature of the crystallization Tc,i,, no crystallization occurs and therefore no
heat is generated:
(jm= 0 for T(t,X) > T,,ist (2)
2. The crystallization is finished when all heat of crystallization is released and no
more material is able to crystallize. That occurs when the calculated heat released
by crystallization of the chocolate layer reaches the total enthalpy of crystalliza-
tion of chocolate, Qcrist.
These conditions are implemented in the model as a product of two functions
fi (em> and f’(T) t o calculate the specific heat of crystallization per time unit &,:
 Modelling the cooling kinetics of chocolate coatings 377

iim=f~(QnJ.fzV’) (3)
The functionsf, andf, with their parameters will be described below.

Dependence of the heat of crystallization f,(Q,,,) being already released

The plot of this function is assumed as to be shown in Fig. 4. It is based on the
following considerations: if the crystallized part of the chocolate is still small, a rapid
crystallization will occur, characterized by the initial steep slope of the function. If
non-crystallized material decreases during the later stages of crystallization, the rate
of crystallization also decreases (second part of the function).
Converting this into a mathematical form, the calculation off, takes into account
the parameter Q,-rist as the value for the maximum possible heat of crystallization. A
second parameter fm describes the value for the steepness of the function and
therefore the starting rate of crystallization within the chocolate. The last parameter
Q maxcharacterizes the position of the maximum off, as shown in Fig. 4. According
to the crystallization behaviour, QmaX describes the dependence of the rate of
crystallization on the amount of non-crystallized material. The lower the value of
Q”,,, is, the higher is the slope of crystallization rate at the beginning of the
crystallization.
The initial slope m, of the function f,(Q,,,) is therefore mi = flm/Qmax, whereas the
final slope mf is

f
I
____________.
f
lm

I
Fig. 4. Plot of the function
Q t?MX Qm
f,(Q,,,) describing the dependence
amount of crystallized material.
> Q
end
of crystallization rate on the
378 K. Franke

f:rn
mf
=Qmax.f lrn -2.Qcrist

Dependence of the temperature fi(T)

Figure 5 shows the function off2 assumed for the model. The parameters describing
the temperature dependence are Tcrist, the initial temperature of crystallization. The
second parameter is the slope f,- characterizing the increase of crystallization with
undercooling (Tcrist- T). These parameters give the following equations for the
dependence of f2 from the actual temperature:

T < Tcrist f*(T) = fT.(Tcrist- T) (5)

i.e. the crystallization starts when the current temperature in a chocolate layer falls
below the initial temperature of crystallization. Below this crystallization tempera-
ture the function is proportional to the degree of undercooling of the chocolate, so
that a higher degree of undercooling causes a higher crystallization rate. A decrease
of crystallization rate at low temperatures caused by an increase of viscosity is not
considered because the chocolate temperature is to high to reach this point at
standard cooling processes.

Tmst T\
Fig. 5. Plot of the function f*(r) describing the dependence of the crystallization rate on the
temperature.
 Modeling the cooling kinetics of’ clzocolute couting,s 379

26

F
- 24
s!
f 23

E 22
8

20
0 1 2 3 4 5 6
cooling time [min]
Fig. 6. Measured and calculated temperature plot of the chocolate coating during cooling.

Altogether, the model includes five different parameters to describe crystallization

within chocolate during cooling (Table 1). The model parameters are estimated by
fitting of cooling temperature curves of enrobed model bodies which are cooled in
a laboratory cooling tunnel under different cooling conditions (Lailach et al., 1995).
These temperature curves were measured using a broad range of air temperatures
and velocities. The used plain chocolate mass was well pre-crystallized.
To find the model parameters the temperature curve calculated by the model was
changed by variation of the parameters in Table 1 until the best fit was reached.
Next, the cooling of chocolate mass was simulated under different conditions in
one or two steps using the model with these best fitted model parameters.

TABLE 1
Parameters Characterizing the Crystallization Behaviour

Description

overall specific heat of crystallization generated in the chocolate during cooling

value for the initial rate of crystallization
dependence of the rate of crystallization from the amount of non-crystallized
material available
initial temperature of crystallization
dependence of the rate of crystallization from the undercooling
380 K. Franke

TABLE 2
Mean Values of Crystallization Parameters for Plain Chocolate

Parameter Unit Mean value Relative standard

deviation (%/

kJ/kg 60.3 11.2

- 1.6 6.7

CT,,!
fmTr “C
kJ/kg 26.5
6.8 11.4
1.4
fT 1/K 0.00043 18.3

RESULTS

Figure 6 shows for one example a comparison between the measured temperature
curve and the calculated curve using the optimal model parameters for this curve.
One can see that the used model is able to fit the general temperature course
including the plateau phase caused by release of heat of crystallization.
The parameters of crystallization for the used chocolate summarized in Table 2
are mean values of eight different cooling trials each carried out under different
conditions of air velocities and temperatures. Additionally, the relative standard
deviation, the ratio of the standard deviation and the respective mean value of the
parameter, is shown to indicate the suitability of the chosen model parameters for
describing the crystallization behaviour. If these parameters are real material con-
stants as assumed, they should be independent of the used cooling conditions and
the standard deviation should be relatively small. Vice versa, a high value of this
standard deviation at all parameters means that the chosen model is unsuitable for
describing the crystallization behaviour or that other factors influencing the crystalli-
zation process have not been taken into consideration. The standard deviations in
Table 2 show the model parameters are suitable.
The determination of the relationships between maximum crystallization rate on
the coating surface and coating gloss properties during storage was based on com-
mercial investigations on chocolate coating cooling (Lailach et al., 1995). Significant
correlations were found between these parameters with an correlation coefficient of
0%

SIMULATION OF COOLING PROCESSES

As an example, a simulation was carried out for chocolate enrobed cookies. The
thickness of the cookies is assumed to be 6 mm and that of the chocolate coating
2 mm, respectively. The thermal properties of the cookie are taken from a collection
of thermal properties of foods (Tschubik & Maslow, 1970). The values for density,
specific heat capacity and thermal conductivity are 600 kg/m3, 15 kJ/(kg*K) and
0.1 W/(m*K), respectively. The initial temperature of the cookies is 22°C before
cooling.
Figures 7a and 7b present the calculated crystallization rates in different layers of
the chocolate during ‘radiation’ cooling (Fig. 7a) without forced convection, and
 Modelling the cooling kinetics of chocolate coatings 38 1

35
- - 0,4 mm (bottom)
30 --
-.-- 1,2 mm (middle)
-2,0 mm (surface)
25 --

20 --

15 -.

10 ~-

0 60 120 160 240 300

cooling time [s]

35/
30 --
- - 0,4 mm (bottom)

25 --

20 --

15 --

10 --

5 --

O-1
0 120 160
cooling time [s]
Fig. 7. (a) Calculated temperature plot in different layers of the chocolate coating during
‘radiation’ cooling. (b) Calculated temperature plot in different layers of the chocolate
coating during cooling by forced convection.
382 K. Franke

during convection cooling for a cooling time of 5 min and a single-step cooling (Fig.
7b).
One can expect that the radiation cooling gives better surface gloss of the choc-
olate because of lower rates of crystallization. On the other hand, the cooling
process is not complete after 5 min because the rate of crystallization at the end of
the cooling time is still rather high, i.e. chocolate coatings cooled under these
conditions are too soft for packaging.
Figures 8 and 9 demonstrate possibilities to optimize the cooling conditions by
dividing the cooling process into two steps. Calculated crystallization rates of the
surface chocolate layer are shown in Fig. 8 for a two-step cooling with different
cooling times within the first step. The overall cooling time is constant. The cooling
conditions of the first step correspond to that of Fig. 7a (‘radiation’ cooling), while
the second step is carried out with forced convection according to Fig. 7b. The
curves of these two single-step processes are displayed for comparison.
One can see that the two-step cooling process does not automatically lead to a
lower crystallization rate and better gloss properties. If the time for the first cooling
step is too short (for example 2 mini3 min), relatively high crystallization rates can
occur during the second step. Therefore, it can be expected that the gloss properties
of the chocolate coating will not be optimal with this step design. A longer cooling
time of the first step (for example 3 min/2 min) is more favourable under these
cooling conditions and for the cookie properties in the example.
In contrast, Fig. 9 shows the simulation results of the effect of the same cooling
conditions but at an initial temperature of the cookie of 19°C instead of 22°C in the
previous examples. The decrease of the cookie temperature leads to the expected
higher rate of crystallization also during pure radiation cooling. In addition, one
recognizes that the cooling time of the first step could be reduced to 2 min. The
reason for this is the higher degree of bulk crystallization in the first cooling step, so
that the maximum crystallization rate of the second step with forced convection
cooling is lower. The benefit is that this longer residence time under forced cooling
conditions gives a more complete bulk crystallization within the chocolate. This
results in a firmer coating which is easier to handle in packaging.

CONCLUSIONS

The proposed model is able to describe the crystallization process of chocolate

coatings during cooling in the cooling tunnel. The model parameters were estimated
by fitting of temperature curves measured under different cooling conditions with
respect to air temperature and velocity. The good fit of the measured curves by the
model and the relatively small deviation among the single fitted crystallization
parameters show the suitability of the proposed model. Using this model a typical
two-step cooling process of an enrobed cookie was simulated. There exists an
optimal time ratio of the two steps by which a product with the best quality can be
expected. However, if one of the conditions such as the initial temperature of the
cookie is changed, the optimal time ratio is shifted and an new adjustment of the
cooling tunnel is necessary. In addition to the influence of the cookie temperature,
parameters such as air temperatures or specific heat and density of the enrobed
centre influence coating crystallization rates in cooling tunnels and therefore the
gloss properties and the quality of the chocolate enrobed product. Using the model
 Modelling the cooling kinetics qf chocolate coatings .M3

.
4

0
0 60 120 160 240 300
cooling time [s]
Fig. 8. Calculated temperature plot of the surface of the chocolate coating during two-step
cooling with different cooling times within the first step and an initial centre temperature of
22°C.

40

FE 35

5 30
Y
$ 25

S
‘; 20
N
E
3 15
6
0 10

$ 5
bY

0
0 60 120 160 240 300
cooling tim [s]
Fig. 9. Calculated temperature plot of the surface of the chocolate coating during two-step
cooling with different cooling times within the first step and an initial centre temperature of
19°C.
384 K. Franke

presented, the effects of these influencing parameters can be simulated under dif-
ferent conditions. This simulation gives the chocolate manufacturers the option of
choosing the best cooling conditions for their specific product without expensive
production trials.

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