Chocolate Manufacture

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Chocolate Manufacture
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Key elements of chocolate for the confectioner

• Flavor
• Color
• Particle size (fineness)
• Viscosity
• Fat content
• Melt properties (cocoa butter hardness)

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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

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Milk Chocolate Standard 21 CFR
163.130

• Chocolate liquor 10 minimum
• (no maximum)
• Milk - 12 minimum
• Milk Fat - 3.39 minimum

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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!

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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

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

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CONFECTIONERY COATING MANUFACTURING
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Sensory of Chocolate Confectionery Coating

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Mixing, Refining, and Conching
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Batch Mixing

Mix raw materials and a portion of the fat
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RD Batch Mixing
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Refining Line
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Chocolate Paste (Before Refining)
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Chocolate Refiner Line
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5 Roll Refiner
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Relationship of Pre-Refining and Final Refining
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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

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Refiner Flake
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Refiner flake traveling to Conche
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Micrometer
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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

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Particle Analyzer

• Scattered Light
• Measure scatter
• Amount
• Direction
• Calculates
• Size Distribution
• Fast QC Check

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Sensory of Particle Size

• Taste and evaluate each piece
• For
• Sweetness
• Mouthfeel
• Melt
• Flavor Release

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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
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Conching

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

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Frise DUC-6 Conche
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Refiner Flake Feeding Conche
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High Shear Conches East Greenville
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Conching
Pilot Frisse Conche
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Sensory of Conching

• Focus on
• Degree of Chocolate
• Sweetness
• Caramel
• Dairy

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ViscosityWhat is it and how is it measured

• Viscosity
• Resistance to flow
• (thickness / thinness)
• Rheology
• The science of the deformation
• and flow of fluids

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Viscosity Check
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Viscosity Ranges for Chocolate Use
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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

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Chocolate Storage ProblemsBefore 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

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Viscosity impacts

• Confectioners handling of chocolate
• Coverage percent
• Dipping Thickness uniformity
• Enrobing Side coating
• Molding Feet / tails
• Air bubbles
• Decoration
• Pumping
• Tank agitation

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Air Bubble Release in Agitated Kettle
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Feet or Slump on Sides of Finished Goods
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Drop Depositing
Requires High Yield Value
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Chocolate pumping after Conching
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Liquid Chocolate Loading
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Liquid Chocolate Ready to Deliver
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10 lb Chocolate Bar Depositing
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10 lb Bar Packaging
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Warehousing Chocolate Products
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Thank You - Questions???
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