Guilt-Free Chocolate...

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Guilt-Free Chocolate...

• Chocolate Manufacturing
• and
• Food Processing

2
Learning Objectives

• By the end of this lesson students will
• be able to describe the industrial process for
  chocolate manufacture from bean to bar
• be able to identify economic and political issues
  involved in the trade of cacao
• be able to identify major chocolate manufacturing
  companies
• be able to identify benefits of sustainable cocoa
  cultivation
• be able to list some Good Manufacturing Practices
  for food handling

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Learning about Chocolate

• History of Chocolate
• Economics of Chocolate
• Engineering of Chocolate
• EPSI Chocolate Cookie Project

www.chocolateandcocoa.org
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Chocolate Manufacturers Association

• CMA's mission is to serve as the voice of the
  American chocolate industry and through research,
  education and public information, works to ensure
  a continued supply of cocoa and increased
  consumption of high value and quality chocolate
  products for the American people.

www.chocolateandcocoa.org
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• ADM Cocoa
• http//www.admworld.com/products/cocoa.htm
• Barry Callebaut USA, Inc.
• http//www.barry-callebaut.com/
• Blommer Chocolate Company
• http//www.blommer.com/
• Guittard Chocolate Company
• http//www.guittard.com/

• Hershey Foods Corporation
• http//www.hersheys.com
• MM/MARS
• http//global.mms.com/us/index.jsp
• Nestle Chocolate Confections
• http//www.nestle.com/
• World's Finest Chocolate
• http//www.worldsfinestchocolate.com/
• Wilbur Chocolate, a Cargill Foods Company
• http//www.wilburchocolate.com/index.html

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Chocolate world

• The cocoa plant is scientifically named Theobroma
  cacao.
• Theobroma -- Greek word 'food of the gods'
• cacao -- from Aztec word cacahuatl.
• Toltecs, Mayas, and Aztecs first enjoyed the
  fruit of the divine cocoa tree.
• Spain and Italy helped introduce the cocoa bean
  to the rest of the world.
• Today cocoa is an international trading
  commodity

Barry Callebaut, USA Inc. 2002
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History of Chocolate

• 1519 -- Conquistidor, Don Hernan Cortez took
  cocoa from Mexico to Spain
• 1606 -- Francesco Carletti brought cocoa from
  Central America to Italy
• 1825 -- Cocoa press invented in Holland by Van
  Houten
• 1828 -- Alkalization process invented
• 1875 -- First milk chocolate produced

www.chocolateandcocoa.org
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Cocoa Producing Countries
Near the equator, high T and high humidity
Barry Callebaut, USA Inc. 2002
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Cocoa producers

• Amazon basin
• 20 of world Cocoa is from Central and South
  America
• Phillipines and West Indies
• 17th and 18th Centuries
• West Africa
• 19th Century
• Ivory Coast Nigeria

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Chocolate Consumers
Barry Callebaut, USA Inc. 2002
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From Crops to Commodity

• Grow cocoa trees for 4 months
• Open and skin fruit
• Harvest beans
• Ferment on banana leaves
• microbes feed on sugar and pulp on beans
• beans turn brown
• Dried and turned for 14 days
• Sampled for Quality
• Shipped and traded on international market

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Markets for Cocoa Beans

• Open
• Do not integrate chocolate in to their own
  products
• Cargill
• ADM
• Barry Callebaut

• Captive
• Produce chocolate for their own products
• Cadbury
• Nestle
• Kraft Jacobs Suchard

Barry Callebaut, USA Inc. 2002
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Economics of Cocoa

• Small Farms -- 90 of world cocoa on 5-10 acre
  farms
• Market price impacts plant quality
• Challenges with pests and disease impact market.

http//www.candyusa.org/CocoaTree/sustain.htm
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Trading Cocoa

• Supply and Outlook -- Ivory Coast produces the
  most cocoa. Weather issues during harvesting will
  increase the price of cocoa futures.
• http//www.chocolateandcocoa.org/Supply/supplyinde
  x.htm
• Demand -- Most cocoa is consumed in the U.S. and
  Europe, but Asian countries are beginning to
  import cocoa.
• http//www.chocolateandcocoa.org/Supply/demand_pri
  ces.htm

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Political Issues

• The IMF (International Monetary Fund) and the
  World Bank, have attempted to help poor countries
  with international debts by altering the world
  cocoa market.
• Recently, Ivory Coast opted for liberalization
  removing government controls on the cocoa market.
  A power struggle over control of the market
  ensued.
• Issues of slavery, child slavery, and child labor
  in the Ivory Coast cocoa industries continue to
  worry chocolate manufacturers.

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Dealing with Slavery...
Persuaded by anti-slavery groups and the threat
of U.S. legislation, chocolate manufacturers in
2001 endorsed a four-year plan to identify and
address instances of abusive child labor in
cocoa-growing countries in West Africa. They
signed a protocol, which sets a series of
deadlines through 2005 to lay groundwork for
monitoring and remedying abusive forms of child
labor in those countries.
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Guilt-Free Chocolate... From Bean to Bar

• Chocolate Manufacturing
• and
• Food Processing

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Bean to Bar Process

• Clean and inspect beans --
• de-dusted
• de-stoned
• passed through metal detector
• Roast beans
• sterilizes and adds aroma
• Break beans and grind nibs
• separate nibs and shells
• sizing and milling
• Prepare cocoa mass
• Squeeze out cocoa butter

• Fine Rolling
• cocoa mass sugar dark chocolate batter
• cocoa mass sugar milk milk chocolate batter
• Conching
• Kneading machine
• removes water and acid
• add fat and cocoa butter
• pump to storage tanks
• Tempering
• heat treatment
• brings cocoa butter to stable crystal form

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Watch Chocolate Processing...

• Note Major Pieces of Equipment
• Note Safety Issues in the Facilities
• What household items, analogous to the processing
  equipment, would enable you to make your own
  personal chocolate?

http//www.candyusa.org/CocoaTree/index.htm
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Brainstorm

• List food-handling considerations in your home?
• How might these principles be implemented on an
  industrial scale?

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Good Manufacturing Practices
GMP -- regulations developed by the FDA under the
authority of the Federal Food, Drug, and
Cosmetic Act Require that manufacturers,
processors, and packagers of drugs, medical
devices, some food, and blood take proactive
steps to ensure that their products are safe,
pure, and effective. GMP regulations address
issues including recordkeeping, personnel
qualifications, sanitation, cleanliness,
equipment verification, process validation, and
complaint handling.
http//www.gmp1st.com/gmp.htm
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Elements of GMP

• The plant management shall take all reasonable
  measures and precautions to ensure the
  following
• Disease Control
• Cleanliness
• Education and Training
• Supervision

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GMP -- Cleanliness

• Wearing outer garments that protect against the
  contamination of food, food-contact surfaces, or
  food packaging materials.
• Maintaining adequate personal cleanliness.
• Washing hands thoroughly (and sanitizing if
  necessary)
• Removing all unsecured jewelry and other objects
  that might fall into food
• Maintaining gloves, if they are used in food
  handling, in an intact, clean, and sanitary
  condition
• Wearing, where appropriate, in an effective
  manner, hair nets, headbands, caps, beard covers,
  or other effective hair restraints

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GMP -- Cleanliness

• Storing clothing or other personal belongings in
  areas other than where food is exposed or where
  equipment or utensils are washed.
• Confining the following to areas other than
  where food may be exposed or where equipment or
  utensils are washed eating food, chewing gum,
  drinking beverages, or using tobacco.
• Taking any other necessary precautions to
  protect against contamination of food, with
  microorganisms or foreign substances including,
  but not limited to, perspiration, hair,
  cosmetics, tobacco, chemicals, and medicines
  applied to the skin.

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Coating Cookies with Chocolate

• EPSI Team Project

http//www.wilburchocolate.com/docs/applications/b
akery/chocolate_coatings.html
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EPSI -- Cookie Coating Project

• Coat cookies with chocolate.
• Estimate average and standard deviation of cookie
  mass, before and after coating.
• Estimate average and standard deviation of the
  coating thickness.
• Calculate nutritional value of the new cookie
  product, including an ingredient list.
• Write a report of your project activities.
• Present your project results in class.

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Available equipment and supplies

• Cookies, chocolate chips, chocolate almond bark
• Bowls, trays, wax paper, and kitchen utensils
• Microwaves
• Kitchen scales and calipers
• Refrigerator

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Project Assignments
Project 2 Chocolate-Coated Cookies Progress Report (team) Oct. 14 (email by 5 pm) 10
Written Report (team) Oct. 21 (class) 50
Teamwork (ind) Oct. 21 (class) 20
Presentation (team) Nov. TBA (in-class) 25