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Chocolate Manufacture

Chocolate Manufacture. Key elements of chocolate for the confectioner. Flavor Color Particle size (fineness) Viscosity Fat content Melt properties (cocoa butter hardness). Chocolate Standards–Essentials. Only cocoa butter and butter oil permitted fats

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Chocolate Manufacture

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  1. Chocolate Manufacture

  2. Key elements of chocolate for the confectioner • Flavor • Color • Particle size (fineness) • Viscosity • Fat content • Melt properties (cocoa butter hardness)

  3. 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

  4. Milk Chocolate Standard 21 CFR § 163.130 • Chocolate liquor 10% minimum (no maximum) • Milk - 12% minimum • Milk Fat - 3.39% minimum

  5. 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 • No maximum liquor level!

  6. White Chocolate Standard21 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 • No flavorings that mimic flavor of chocolate, milk, or butter

  7. Mixing Ingredients CHOCOLATE MANUFACTURE Prerefining 5-Roll Refining Conching Standardizing Chocolate Liquid Holding Depositing or Molding Discs or Drops 10 lb. bars Tankers

  8. 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 • Sugarfree chocolate flavored ctgs.

  9. CONFECTIONERY COATING MANUFACTURING

  10. Sensory of Chocolate & Confectionery Coating

  11. Mixing, Refining, and Conching

  12. Batch Mixing Mix raw materials and a portion of the fat

  13. R&D Batch Mixing

  14. Manufacture of Chocolate Masses Pre-refining Conching Ingredient bins 1 3 5 Electric plant control Final refining Mixing / kneading 2 4 6 Refining Line

  15. Chocolate Paste (Before Refining)

  16. Chocolate Refiner Line

  17. 5 Roll Refiner

  18. Relationship of Pre-Refining and Final Refining

  19. Mechanical Size Reduction in Chocolate • Prerefiner 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 • Envelope particles with fat

  20. Refiner Flake

  21. Refiner flake traveling to Conche

  22. Micrometer

  23. 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

  24. Scattered Light Measure scatter Amount Direction Calculates Size Distribution Fast QC Check Particle Analyzer

  25. Taste and evaluate each piece For : Sweetness Mouthfeel Melt Flavor Release Sensory of Particle Size

  26. Why Different Particle Size? Boxed Chocolates – 10 –20 microns Inclusions - 15- 45 microns Chocolate Chips – 15-35 microns Novelty items – 15-45 microns Solid Pieces – 10-25 microns Truffles – 10-15 microns

  27. Conching • Flavor Development • Energy into Mass (Shearing & Heat) • Conching Time • Conching Temperature • Rounding Particles (Texture) • Volatile Removal

  28. Frise DUC-6 Conche

  29. Refiner Flake Feeding Conche

  30. High Shear Conches – East Greenville

  31. Conching Pilot Frisse Conche

  32. Focus on: Degree of Chocolate Sweetness Caramel Dairy Sensory of Conching

  33. 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

  34. Viscosity Check

  35. Viscosity Ranges for Chocolate Use

  36. 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

  37. 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

  38. Viscosity impacts: • Confectioner’s handling of chocolate Coverage percent • Dipping Thickness & uniformity • Enrobing Side coating • Molding Feet / tails Air bubbles Decoration • Pumping • Tank agitation

  39. Air Bubble Release in Agitated Kettle

  40. Feet or Slump on Sides of Finished Goods

  41. Drop Depositing Requires High Yield Value

  42. Chocolate pumping after Conching

  43. Liquid Chocolate Loading

  44. Liquid Chocolate Ready to Deliver

  45. 10 lb Chocolate Bar Depositing

  46. 10 lb Bar Packaging

  47. Warehousing Chocolate Products

  48. Thank You - Questions??? Why am I in Here?

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