CHOCOLATE COMPANY
Chocolate Manufacture
Key elements of chocolate for the confectioner
Flavor Color Particle size (fineness) Viscosity Fat content Melt properties (cocoa butter hardness)
Chocolate StandardsEssentials
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
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 Chocolate
Chocolate liquor 35% minimum Milk - 12% maximum o 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 o flavorings that mimic flavor of chocolate, milk, or butter
Mixing Ingredients Prerefining 5-Roll Refining Conching Standardizing
CHOCOLATE MANUFACTURE
Chocolate
Depositing or Molding
Discs or Drops 10 lb. bars
Liquid Holding
Tankers
Confectionery Coatings
Current CFR Typically NOT Used Referred to as Confectionery Coating Cannot be labeled as Chocolate Fat other than Cocoa butter used
Lauric, Nonlauric vegetable fats
Flavorings not limited Sugar free chocolate flavored ctgs.
CONFECTIONERY COATING MANUFACTURING
COATING MANUFACTURE
MIXING-WET
MIXING-DRY
BALL MILLING
PREREFINING
DRY GRINDING
STANDARDIZING
5 ROLL REFINING
MIXER/KNEADER
STANDARDIZING
STANDARDIZING
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
1 Ingredient bins
Pre-refining
5 Conching
2 Mixing / kneading
4 Final refining
6 Electric plant control
Chocolate Paste (Before Refining)
Chocolate Refiner Line
5 Roll Refiner
Differential Relationship of Pre-Refining and Final Refining Ratio Gear Vorwalzwerk Pre-Refiner Prbroyeuse SZAN Prerefinadora SZWA
SZAE
Diffrentiel Diferencial
W2 : W5
W1 W2
1 : 5
1 : 10
Vorwalzfeinheit Pre-refined particle size Finesse de prbroyage Finura del prerefinado
70-100 m 140-200 m
W5
20 m 20 m
W4
W3
Fnfwalzwerk SFLA Five-Roll Refiner Broyeuse 5 cyl. SFLE Refinadora de 5 cil. SFLN
W1
W2
70-100 m 140-200 m
Mechanical Size Reduction in Chocolate
Pre refiner conditions mass Finished refining completes particle reduction Rolls slightly crowned
Pressure exerted Thin film forms on rolls
Speed of rolls
Increase bottom to top Creates shearing action
Gap adjustment based on final fineness nvelope particles with fat
Refiner Flake
Refiner flake traveling to Conche
Micrometer
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 repairfree movement, not catching Put away clean with the anvils slightly open
Particle Analyzer
Scattered Light Measure scatter
Amount 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 Inclusions 15- 45 microns
Chocolate Chips 15-35 microns
Novelty items 15-45 microns
Truffles 10-15 microns
Solid Pieces 10-25 microns
Conching
Flavor Development
Energy into Mass (Shearing & Heat) Conching Time Conching Temperature
Rounding Particles (Texture) Volatile Removal
Frise DUC-6 Conche
Doppel-berschlag-Conche Double-Overthrow Conche Conche double effet Concha de doble volteo
D C -G
R e ch tslau f C lockw ise rota tio n A M a rche d roite G iro a la de re ch a Linkslau f A nti-clockw ise rota tio n B M a rche g auche G iro a la izq uie rd a
B
X Y
D o ppe lm a nte l W ate r jacket X E nvelo ppe do uble C a m isa dob le Isolation sschich t In su latio n layer Y C o uche d'iso latio n C a pa d el aislam ie nto
Refiner Flake Feeding Conche
High Shear Conches East Greenville
Conching
Pilot Frisse Conche
Sensory of Conching
Focus on: Degree of Chocolate Sweetness Caramel Dairy
ViscosityWhat 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 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 pansalso microbiological issue)
Moisture pickup
From high RH storage, thickens chocolate
Viscosity impacts:
Confectioners handling of chocolate
Dipping Enrobing Molding Coverage percent Thickness & uniformity Side coating Feet / tails ir bubbles Decoration
Pumping Tank 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???
Why am I in Here?
