Res Course WK 2 CH9 A1 Chocolate

Chocolate—Food of the Gods!
Thalia Hohenthal
Guittard Chocolate Co.
Resident
Course in
Confectionery
Technology
Outline
• Where does Cacao come from?
• How is chocolate made? (Optional: The Story of Chocolate Video –
NCA)
• Standards of identity
• Receiving and storage of chocolate prior to use
• Melting chocolate for use and tempering
• Selection and specification of chocolate
♦ Fineness and Viscosity (including brief summary of measurement)
♦ Enrobers
♦ Molding
♦ Panning
• Cooling, packing, and finished product storage

• Bloom and Bloom Diagnostics
• Shipping finished products
Resident Course in Confectionery Technology

2
Theobroma Cacao—Food of the Gods

3
Source of Cacao
• Third world countries all 15-20 degrees of Equator
• Top producing cocoa countries: Ivory Coast, Ghana
♦ Also Indonesia, Nigeria, Cameroon, Brazil, Ecuador and
Malaysia
• 85-90% of world crop grown by small farmers (less than 5
ha)—the family farm

4
Flowers on main branches and trunk

5
Flowers

6
Flower bud and cherelle

7
A productive tree

8
Pod

9
Harvesting is a manual selection

10
Sorting to remove diseased beans

11
Fermenting

12
Drying in yard

13
Large scale drying—on rollers in case of rain

14
How is Chocolate Made?

15
Sample Milk Chocolate-Minimum Composition
53.4% Sugar
24.2 Cocoa butter
12.0 Dry whole milk
10.0 Chocolate liquor
0.3 Lecithin
0.1 Vanillin (an artificial flavor)

16
Simplified Process Flow Chart
Raw Cocoa
Beans
Cleaning
Roasting
Shell Removal
Nibs to Liquor
Milling
Sugar
Liquor Pressing
O ther Ingredients
Press Cake Cocoa Butter Chocolate Mixing

Filtering
Cocoa Powder
Refining
Milling
Conching
Packing
Tank Adjustment
Tempering
Depositing
Cooling Tunnel
Resident Course in Confectionery Packing

Technology
17
Typical Bean Blends
• Chocolate Manufacture • Cocoa Powder Mfg.
• Base ♦ Ivory Coast
♦ Ivory Coast/Ghana ♦ Nigeria
♦ Indonesia (cost) ♦ Indonesia
• Flavor ♦ Malaysia
♦ Arriba (Ecuador) • Color
♦ Venezuela ♦ Cameroon
♦ Trinidad
♦ New Guinea
♦ Java

18
Flavor Control
• Fermentation
• Bean Blend
• Roasting
• Nib / Liquor Treatment
• Mixer Formula
• Conching

19
Cacao Plant Cell–Cotyledon

20
Barth Batch Roaster for Cocoa Beans or Nibs

21
Nib Grinding
• Efficient removal of cocoa butter from within the cell

(20-30 μm in size)
• Fibrous and tough - shear required
• Final maximum particle size 15-50 μm
• Accomplished in two steps
• Influenced by shell content, degree of roasting,
alkalization

22
Cocoa Pressing

23
Chocolate Refining
• Grinding requirements depend on chocolate type

and end use
• Five-roll refiners most commonly used
• Sizes sugar and milk particles

24
Five Roll Refiner SFLA
Front Side Access

25
Frisse Double-Overthrow Conche
DÜC -6

26
Standards of Identity for Chocolate
Federal Standards of Identity-21 CFR §
♦ Chocolate Liquor (163.111)
♦ Cocoa Powder (10-12%) (163.113)
♦ Breakfast or High Fat Cocoa (22-24%)
(163.112)
♦ Milk Chocolate (163.130)
♦ Dark Chocolate (163.123)
− Sweet Dark
− Semi-sweet or Bittersweet
♦ White Chocolate (163.124)

28
Chocolate Standards–Essentials
• Only cocoa butter and butter oil permitted fats
• Chocolate flavor from chocolate liquor only
• Only “nutritive carbohydrate sweeteners”
permitted
• No flavors simulating chocolate or dairy
permitted

29
Milk Chocolate Standard–21 CFR § 163.
• Chocolate liquor 10% minimum

(no maximum)
• Milk 12% minimum
• Milk Fat 3.0% minimum

30
Dark Chocolate Standard–21 CFR §163.
• Sweet Dark Chocolate

♦ Chocolate liquor 15 min 35 max
♦ Milk Fat 12% maximum
• Semi-sweet / Bittersweet Chocolate

♦ Chocolate liquor 35% minimum
♦ Milk Fat 12% maximum
♦ No maximum liquor level!

31
Dark Chocolate–Example Compositions
• Minimum Semi-sweet • 70% Bittersweet
50.4% Sugar 29.4% Sugar

35.0% Chocolate liquor 70.0% Chocolate liquor
14.0% Cocoa butter -- Cocoa butter
0.3% Lecithin 0.3% Lecithin
0.1% Vanillin 0.3% Vanilla
(an artificial flavoring)

32
White Chocolate Standard—21 CFR 163.124
• Only fats permitted are cocoa butter and butter

oil (added as is or via milk components)
• Same permitted dairy ingredients as milk
chocolate
• No added flavors to simulate the flavor of milk

33
Receiving, Storing, and Melting Chocolate
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
35
Chocolate Storage
• Constant temperature is best

Recommend 60-70°F, 50% RH max.
• Free of all strong odors
Be particularly aware of “air conditioning” odors
• First in — First Out stock rotation
Teach personnel how to read code dates

36
Chocolate Storage Problems–Before Use
• Pick up of off odors from the storage area
♦ Other 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 pickup
♦ From high RH storage, thickens chocolate
37
Moisture Absorption in Storage
• Type of chocolate or compound makes a
difference
♦ Dark << Milk << White
• Issue of temperature and relative humidity
• RH less than 50% highly recommended
• Form is important
♦ 10 lb. Bars << wafers or ribbons or chunks
• Protect with packaging / air tight containers

38
Chocolate Melting
• Temperature sensitivity
♦ White > Milk >>>>> Dark
• Ideal jacket temperatures
♦ Dark 160 - 180 °F
♦ Milk 140 - 160 °F
♦ White 120 - 140 °F
• Watch out for “hot spots”
♦ Steam entry point
♦ Poor agitation, agitator not clearing surface
39
Chocolate Selection by the Confectioner
Key elements of chocolate for the confectioner
• Flavor
• Color
• Particle size (fineness)
• Viscosity
• Fat content
• Melt properties (cocoa butter hardness)

• pH (for baking performance)

41
Cocoa Butter Melting Profile
80
hardness / snap
70
60
% solid fat
50
heat flavor release
40 resistance cooling sensation
30
20 waxiness
10
0
50F 70F 80F 92F 96F 100F
temperature

42
Particle Size Measurement

43
Matching Fineness to Centers

44
Particle size measurement
• Hegman gauge
• Micrometer (AACT Method)
• Microscopy / Image analysis
• Sedimentation, centrifugation
• Sieve
• Electrical zone sensing (Coulter)
• Light scattering– laser (Microtrac)

45
Micrometer

46
Micrometer Fineness Method–
American Association of Candy Technologists (AACT)
Upper Rotating Anvil
Lower Stationary Anvil

47
AACT Micrometer Fineness Method
• Rotating micrometer must be used
• 50 / 50 Oil and chocolate well mixed
• Micrometer cleaned and zeroed
• Temperature sensitive
• Consistent slip or ratchet clutch between
technicians and micrometers
• Micrometer in good repair–free movement, not
“catching”
• Put away clean with the anvils slightly open

48
The micrometer Vernier scale (US measure)
Vernier Scale Thimble Scale
10 10 (Turns)
9 9
Alignment at 8 8 8
7 7
6 6
5
5
4
4
3
3
2
2
1
1
0
0
25
24

49
US to metric conversion
Ten-thousandths of an inch Microns
3 7.6
4 10.2
5 12.7
6 15.2
7 17.8
8 20.3
9 22.9
10 25.4
11 27.9
12 30.5
13 33.0
14 35.6

50
Viscosity
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

52
More definitions
• Shear rate
♦ How fast we are attempting to move the
chocolate
♦ rpm of the viscometer
♦ Designated by “DN”, units: seconds-1
• Shear Stress
♦ Force with which the chocolate resists flow
♦ Result of the shear rate
♦ Designated by Greek letter, tau, “∴CA”, units:
2
dynes/cm
53
Bingham Plastic Foods
ketchup
mayonnaise
Shear Stress
τ
whipped cream
meringue
Shear Rate D
54
Definition
• Plastic Viscosity, PV
Force to keep the mass in motion when it is
already moving
measured in “poise”
• Yield Value, YV
Force to start the mass flowing when it is at
rest
2
measured in “dynes/cm
55
Viscosity of various materials
Hi PV
Hi PV
Lo YV Heavy, thick flowing Thick, stiff Hi YV
but no string, like ___________
like__________
PV
Has "standup" but

Flows like flows easily
___________ like ____________
Lo PV Lo PV
Lo YV Hi YV
YV
Chocolate viscosity
2
(1/Slope) =PV
(1 + a ) DN
2
1/2 (Intersect) =YV
(1 + a ) τCA

57
Molten chocolate is a
concentrated suspension of 40-70

volume percent of sugar, cocoa and
milk particles in liquid fat.

58
Viscosity is influenced by:
• Fat Content
• Moisture
• Surfactants
• Temperature
• Structural attributes of the particulate phase

59
These attributes include:
• Particle size
• Particle size distribution
• Particle shape
• Particle density

60
In general, viscosity decreases as:
• Particle size increases

• Particle size distribution broadens
• Particles become more spherical

61
Effect of solids loading (fat content)
Maximum Solid Concentration Effects

on Suspension Viscosity
1000
Relative Viscosity
100
10
1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Solid Volume Fraction
φm = 0.60 φm = 0.75

62
Particle size distribution

63
Viscosity impacts:
• Confectioner’s handling of chocolate
Coverage percent
♦ Dipping Thickness & uniformity
♦ Enrobing Side coating
♦ Molding Feet / tails
Air bubbles
Decoration
• Pumping
• Tank agitation
64
Viscosity Ranges for Chocolate Use

65
PV / YV Effect on Chocolate Handling
____________________PV___YV___Vibration/Air Blow
Pattern holding X
Feet and tails X
Flat surface coating X X X
Air bubble release X X X
Side and edge coating X X X X
Fill in rough surfaces X X X

66
Air Bubble Release in Agitated Kettle

67
Feet or Slump on Sides of Finished Goods

68
Stringing Caused by High Yield Value

69
Thin corners

70
Pattern Holding on Candies

71
Effect of Added Moisture on Milk Chocolate Viscosity
% Added PV YV YV/PV MacMichaels

Moisture Ratio
0.0 22.3 124 5.57 151

0.1 22.4 126 5.61 152
0.3 24.8 129 5.21 161
1.0 32.8 167 5.09 206
•PV increases
•YV / PV Ratio Decreases

72
Effect of Heat Abuse on Milk Chocolate
Temperature PV YV YV/PV MacMichaels

o
C Ratio
40 22.3 124 5.57 151
71 21.2 124 5.87 148
85 20.6 126 6.12 148
95 19.3 132 6.83 147
100 18.3 141 7.70 149
(Milk chocolate stirred during heating. Total elapsed time 45

minutes)
•PV drops and YV increases

•YV / PV ratio increases significantly

73
Viscosity Units of Measure
2
1 Poise = 1 dyne-sec/cm
10 Poise = 1 Pascal-sec, PaS
1 Poise = 100 centipoise

74
Viscosity measurement samples–
• Should be fresh
Milk chocolate especially can pick up moisture in storage if
unprotected
• Must be gently melted

• Must be fully melted with gentle agitation /
stirring

75
Brookfield Viscometer

76
Adjustment of Chocolate
with Cocoa Butter
Source: Chocolate Production and

Use, Cook/Meursing, 1982

77
Effect of Lecithin on PV and YV
Source: Industrial Chocolate Manufacture and Use, 2ed, Beckett, 1994

78
Tempering

79
Triglycerides take on a tuning fork configuration
C O CH2
CH O
C
C O CH2
O
O

80
T>Tmelt T=Tmelt T<Tmelt
supercooling
True melt Crystal embryos Crystal lattice

81
Consequently there are several types of triglyceride crystals
o
I sub-α 17.3 C
α
o
II 23.3 C
III β'2 25.5oC
IV β'1 27.3oC
V β 33.8oC
β
o
VI 36.3 C

82
Chocolate Polymorphic Forms
Form Crystallizes Melt Range Stability Contraction
Κ <62.5 Up to 52.5 °F unstable
Ι from Κ Up to 75°F unstable 0.060 ml/g
ϑ’ 62.5 - 72.5 °F 59 - 85 °F semi-stable 0.086 ml/g
ϑ 72.5-92.5 °F 68-95 °F stable 0.097 ml/g

83
Key Facts
• Desirable forms have a high melting point

• The higher melting point, the more stable
• More stable fats are more dense
• More stable forms are slow to form
• Like crystals will grow from like
• Cocoa butter can convert from a less to more stable
form

84
Lattice Packing

85
Cocoa butter
• Cocoa butter is largely triglycerides

• There has several stable crystal polymorphs
• Good chocolate can only be made from the stable
crystals

86
Tempering
Tempering is a time-temperature
process ensure the formation of
chocolate in the right crystal habit
In practice this means we want 1-2%

solids at ~32oC which will act as
seeds when the melt is cooled

87
Tempering
• Why temper?
♦ Demolding
♦ Snap
♦ Gloss
♦ Resistance to bloom
• Temperature and time control

88
Chocolate Temper–Key Issues
Temperature Viscosity
# of Crystals
Rate of Cooling Set up speed
Size of Crystals
Time Initial Gloss
Type of Crystals
Agitation Stability
Contraction
Grain / Snap

89
Tempering sequence
50oC
Melt
Cool - no crystallization
Form mix of crystals
Melt out unstable polymorphs
temperature
32oC 30-32oC 1-2% SFC
27oC
time
90
Tempered Chocolate–a microscopic view
Good Temper sugar
cocoa butter
Over tempered
♦ Poor contraction
♦ Poor gloss
♦ Poor stability (blooms)
Poor Temper (over/melted)
♦ % mass is OK
♦ Number / size nuclei wrong
♦ Free path too long

91
Hand Tempering
• Melt fat
• Pour melt onto slab and work with spatulas
• Return crystalline batch back to warm melt
• Mold Chocolate
Melt

92
Kettle Tempering
Melt
93
Nielsen Tempering Machine

94
Batch vs. Continuous
• Simple to operate • Continuous operation

• Good for small • Good for large
quantities quantities
• Easy to clean • Small footprint
• Slow come-up time
• Large footprint

95
Cooling curves
temperature
time
Over tempered GOOD TEMPER Under tempered

96
Tempering
• Tempering is a process to ensure the formation of

stable crystals
• Tempering is a time-temperature process
• Tempering can be done as a batch or continuous
process
• Degree of temper can be measured from a cooling
curve

97
What is bloom?
• White “moldy” appearance at the surface

• Major reason for product failure
• NOT a health hazard
Often caused by large fat crystals growing from the

surface and scattering light

98
99
Types of Bloom
• High temperature bloom

• Low temperature bloom
• Fat migration bloom
Note: Bloom in compound coatings is different!

100
High Temperature Bloom
• Fat is stored hot enough to melt (~35oC)

• Fat resolidifies and is no longer tempered
• Untempered chocolate rapidly grows bloom
U se a high melting fat if you can’t be certain of

distribution temperature

101
Low Temperature Bloom
• In well tempered chocolate stored below its melting

point
• Associated with V to VI transition
• Occurs faster at high temperatures (esp. if temp.
cycles)
Reduce storage temperature

102
Migration Bloom
• The movement of fat from an enrobed center to the

surface
• Dissolves some cocoa butter and caries it to the
surface
• Cocoa butter recrystalizes at the surface

103
How to avoid bloom
• Temper the chocolate properly

• Store cool
• Add butter-fat
• Add emulsifier (e.g. sorbitan monostearate)

104
Enrobing and Molding
Large Enrober

106
Large Enrober--Hopper, Curtain and Blower

107
Enrober with Outboard Tempering
• Uses same enrober as for inboard tempering
• Tempering unit set to deliver 10-15% more
than enrober needs
• Return passes through a “decrystallizer” or
“detemperer” (120°F heat exchanger or tank)
• Tempering unit must always be fed fresh
chocolate, no seed, at 104°F typical.

108
Enrober with Inboard Tempering
1. Wire grid conveyor belt 6. Bottoming trough with surge roller

2. Stirred reservoir tank 7. Air blow-off nozzle
3. Chocolate pump 8. Shaker
4. Cooled tempering riser pipe 9. Licking rolls for bottom control
5. Distributor pan for chocolate curtain 10. De-tailer

109
Strings

110
Enrober Decorator or Stringer with Separate Tempering

111
Enrober Troubleshooting
• Look for sources of heat (pumps, motors, night

heaters, drafts, etc..)
• For inboard tempering use “drip” feed
(maximum addition 10% of trough contents)
• For outboard tempering be certain product is
fully de-tempered (no nuclei)
• Avoid buildup of nut oil in enrober

112
Shell Molding

113
Cooling Chocolate
Mold Cooling Section

115
Cooling Tunnels
• Convection
♦ Cooling tunnels with air blowing to provide
cooling
• Conduction
♦ Cooling provided by “cold slabs”
• “Radiant Cooling”
♦ Cooling provided by coils mounted above
product, no air blowing
♦ Not accurate as convection currents from the
coils provide cooling (see Heat Transfer paper)

116
Cooling Tunnel Operation Cross Section

117
Cooling Tunnel Problems
• Inadequate air blowing
• Air “shadowing” of product
• Over running tunnel
• Too cold exit temperature, condensation, sugar
bloom
• Lack of temperature probes in tunnel
• Air conditioning coil drains become clogged
(high moistures in tunnel)

118
Incorrect Tunnel Air Movement–Shadowing
Direction of air movement

119
Tunnel Air Movement–Shadowing Eliminated
Direction of air movement

120
Shipping and Finished Product Storage
The Finishing Touch!

122
Shipping Finished Goods
• Beware of possible temperature problems
♦ Staging on warm docks (bloom from heat
damage)
♦ Movement from cold room to warm humid dock
(condensation and sugar bloom)
♦ Loss of temperature control in shipment
• Maintain retention samples before movement
• Check temperature and humidity records

123
Finished Product Storage
• Condition goods at 65-68°F for 24-48 hours to ensure full heat
release and set
• Constant temperature is best

Recommend in range 60-70°F, 50% RH max.
• Free of all strong odors
Be particularly aware of “air conditioning” odors
• First in — First Out stock rotation–read code dates
• Caution about humidity and condensation
When working with lower temperatures (sugar bloom)

124
Dull Gray Fat Bloom in Storage of Product
• Sources of heat
♦ Marginal tempering especially coupled with
♦ Centers not sufficiently cooled (typically too short a
tunnel time)
♦ Heat trapped in packaging / packed in well insulated
containers too soon after tunnel
• Nut oil migration
♦ From center (oil roast, damaged or old nuts, vacuum
packed nuts) (affects tops and sides first in thin or low
spots)
♦ Contamination on cooling tunnel and packing belts
(affects bottoms first)
125

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Chocolate—Food of the Gods!

• Cooling, packing, and finished product storage

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Press Cake Cocoa Butter Chocolate Mixing

Resident Course in Confectionery Packing

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

• Efficient removal of cocoa butter from within the cell

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

• Grinding requirements depend on chocolate type

Resident Course in Confectionery Technology

Front Side Access

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

• Chocolate liquor 10% minimum

Resident Course in Confectionery Technology

• Sweet Dark Chocolate

• Semi-sweet / Bittersweet Chocolate

Resident Course in Confectionery Technology

50.4% Sugar 29.4% Sugar

Resident Course in Confectionery Technology

• Only fats permitted are cocoa butter and butter

Resident Course in Confectionery Technology

• Constant temperature is best

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

• Melt properties (cocoa butter hardness)

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Lower Stationary Anvil

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology

Has "standup" but

Resident Course in Confectionery Technology

concentrated suspension of 40-70

Resident Course in Confectionery Technology

Resident Course in Confectionery Technology