Chocolate Industry

These slides have complete information about chocolate history and the process involved in the chocolate industry. Very helpful slides to understand chocolate processing.

1. Chocolate Industry ABDUL RAHMAN TAHIR

2. Chocolate: Chocolate is sweet and delicious food. Chocolate is made from cocoa beans which are got from cacao tree Theobroma cacao. Harvesting of cacao pods when the color change from green or red to yellow or orange . Every pod contains 30 to 45 beans. Beans are separated from pods..

3. History Mayas and the Aztecs were the first people who made chocolate. The drank chocolate as a bitter and spicy beverage that called ‘’xocoatl’’. ‘’Xocoatl means bitter water’’. It was used as medicine . It was a drink for wealthy Royal people and respected Priests. Cocoa beans were used as money due to its importance.

4. History Continued……..

5. History Continued……. In 1815, Dutch chemist ‘’Coenraad Van Houten ’’ introduced alkaline salts to chocolate which reduced its bitterness. A few years thereafter in 1828 he created press to remove about half the natural fat (cocoa butter) from chocolate liquor which made chocolate both cheaper to produce and more consistent in quality. Inn 1875 Swiss chocolatier Daniel Peter invented milk chocolate by mixing powder milk developed by Henri Nestlé with the liquor. In 1879 it was further improved by conching machine. Cadbury was manufacturing box chocolate in 1868.

6. Location: Lahore Sheikhupura road. Cacao beans: Cocoa beans imported from Indonesia.

7. Types of chocolate: White chocolate Milk chocolate Dark chocolate Sweet chocolate Unsweetened chocolate

8. White chocolate: White chocolate contains cocoa butter, sugar and milk but no cocoa solids. Milk chocolate: Milk chocolate is sweet chocolate that additionally contains milk powder or condensed milk. In 1875 Swiss chocolatier Daniel Peter invented milk chocolate by mixing a powdered milk developed by Henri Nestle.

9. Milk chocolate White chocolate

10. Dark chocolate: Pure, unsweetened chocolate contains primarily cocoa solids and cocoa butter in varying proportions. Dark chocolate is produced by adding fat and sugar to cocoa mixture for sweetened dark chocolate. Sweet chocolate: Much of the chocolate consumed today is in the form of sweet chocolate, combining chocolate with sugar.

11. Dark chocolate Sweet chocolate

12. Unsweetened chocolate: Unsweetened chocolate is pure chocolate liquor also known as bitter or baking chocolate. It is unadulterated chocolate : the pure ,ground, roasted chocolate beans impart strong ,deep chocolate flavor.

13. Fermentation: The fresh beans are stored in the wooden boxes for 5 to 7 days. Natural yeast and bacteria multiply in the pulp causing the breakdown of sugars and mucilage. Fermentation kills the beans preventing them from germinating latter. Change in the color of the seed from pale yellow or violet to brown. It develops flavor precursors that are essential for tasty chocolate.

14. Drying: The fermented beans have high moisture content. So the fermented beans are dried up too a moisture level off 6 to 7 %. Then they are bagged and shipped to chocolate industries. Once cocoa beans are dried they can be use for 4 to 5 years.

15. Manufacturing operations in chocolate industry:

16. Cleaning and sorting: In the cocoa cleaning unit, the cocoa beans go through several sieving stages: a coarse sieve, a fine sieve a strong flow of air (aspiration), a metal separator (magnet) a vibratory sieve which remove leaves, fibers, sand, stones and metal from the cocoa beans. Now the cocoa beans have been cleaned of impurities.

17. Cleaning and sorting

18. Roasting the Cocoa Beans: After careful cleaning, the cocoa beans are roasted in roasters, on grills or in large rotating drums using hot air. At temperatures between 130 and 150°C, the beans develop their typical roasted cocoa aroma and dark brown color. This process can take between 10 and 35 minutes. The roasting time depends on the size and variety of the cocoa bean The beans water content continue to drop. During this step, the shells come loose and separate from the kernels. Depending on the intended level of roasting. Bulk cocoa is roasted at slightly higher temperatures than fine or flavor cocoa. Afterwards the beans cool down.

19. Roasting

20. Breaking the Beans: After the roasting, the cocoa husk has separated from the bean it has been significantly loosened. The husk still surrounds the bean. In order to remove it, the beans must be broken. This may be done by using a series of rollers through which the beans pass. The rollers crush the beans, The rollers crush the beans breaking them into pieces, along with the now brittle husk. These pieces are called cocoa bean nibs . The distance between the rollers must be tuned to allow for different sizes of beans.

21. Breaking of beans

22. Winnowing: the cracked beans are passed through the winnower column and cocoa nibs fall into collection box while husk is collected in a separator container. The nibs are collected in the collection tray placed under the winnower column. High yield of nibs with minimum husk ensures high quality nibs. There is negligible amount of nibs in the husk and vice versa with a single pass. Cracking the roasted beans properly is critical to efficient winnowing.

23. Winnowing

24. Alkalization: Natural un-alkalized cocoa has a bitter acidic taste. Alkalization involves adding an alkalizing agent to the cocoa nibs before roasting. Alkalization removes cocoa butter from the solids, resulting in a richer, darker cocoa with a milder taste. Cocoa in its natural form is slightly acidic, with a nominal range of 5 to 5.6 The alkalization process neutralizes the normal cocoa acidity and raises the pH into the 7 to 8 range.

25. Alkalization:  After drying in the alkalizing system, the moisture is evaporated and discharged. A vacuum system can be used to speed up the drying process.

26. Alkalization

27. Continuous Nib Roasting System: In the continuous nib roasting approach, the pre-dried (alkalized) nibs are fed to the roaster. Small batches of nibs are all treated the same way due to the continuous turning of layers. In result, a very uniform flavor development. It is an excellent roasting method due to low energy consumption, flexible flavor development and excellent end-product color. Hot air intake of temperatures 130 to 140 ° C for pre-drying and 170 to 180 ° C for the roasting process

28. Grinding: The roasted nibs are milled through a process that liquefies the cocoa butter in the nibs and forms cocoa mass (or paste). This liquid mass has dark brown color, typical strong smell and flavor and contains about 54% of cocoa butter.

29. Pressing of Cocoa Liquor: Cocoa Pressing Part of cocoa mass is fed into the cocoa press which hydraulically squeezes a portion of the cocoa butter from the cocoa mass, leaving "cocoa cakes". The cocoa butter is used in the manufacture of chocolates; the remaining cakes of cocoa solids are pulverized into cocoa powders.

30. Conching : is a flavor development process during which the chocolate is put under constant agitation. The conching machines, called "conches", have large paddles that sweep back and forth through the refined chocolate mass anywhere from a few hours to several hours. 49 to 82 °C for 10 to 20 hours. Conching , further develops flavor and texture. Conching is a kneading or smoothing process. Conching reduces moisture, drives off any lingering acidic flavors and coats each particle of chocolate with a layer of cocoa butter. The resulting chocolate has a smoother, mellower flavor.

31. Mixing: In Mixing Ingredients, like cocoa mass, sugar, cocoa butter, flavorings and powdered or condensed milk for milk chocolate are blended in mixers to a paste with the consistency of dough for refining. In batch mixing all ingredients are thoroughly mixed normally for 12 to 15 minutes at 40 to 50 °C.

32. Refining: Chocolate refiners, a set of rollers, crush the paste into flakes that are significantly reduced in size. This step is critical in determining how smooth chocolate is when eaten.

33. Tempering: The mixture is then tempered or passed through a heating, cooling and reheating process. This prevents discoloration and fat bloom in the product by preventing certain crystalline formations of cocoa butter developing

34. Tempering involves the following steps: i )Melting to 50 °C. ii)Cooling to point of crystallization 32 °C. iii)Crystallization at 27 °C. iv)Melting out of unstable crystals at 29 to 31 °C. Tempering gives: i )Good surface gloss and color ii)Smooth and fast melting

35. Different crystals of chocolate: Crystal Melting Temperature Notes I 17 °C (63 °F) Soft, crumbly, melts too easily II 21 °C (70 °F) Soft, crumbly, melts too easily III 26 °C (79 °F) Firm, poor snap, melts too easily IV 28 °C (82 °F) Firm, good snap, melts too easily V 34 °C (93 °F) Glossy, firm, best snap, melts near body temperature (37 °C) VI 36 °C (97 °F) Hard, takes weeks to form

36. Tempering

37. Molding: After the chocolate is properly tempered. The mixture is then put into molds or used for enrobing fillings and cooled in a cooling chamber.

38. Molding

39. Cooling and packaging: The molded chocolate enters controlled cooling tunnels to solidify the pieces. Depending on the size of the chocolate pieces, the cooling cycle takes between 20 minutes to two hours. From the cooling tunnels, the chocolate is packaged for delivery to retailers and ultimately into the hands of consumers.

40. Storage: Chocolate is high sensitive to: Temperature Humidity Ideal temperature for the storage of chocolate is between 15 and 17 ºC

41. Blooming Effects Flat Bloom Sugar Bloom Flat Bloom: Flat bloom is dull white color film on surface of chocolate Flat bloom occurs due to 1)Temperature fluctuating 2)Exceeding storage temperature 24

42. Sugar Bloom : Due too sugar bloom chocolate feels dray and hard when we touch it . Sugar bloom caused by: 1) Temperature bellow 15 2) Excess humidity

43. Process flow chart

44. Flow Chart

45. Conclusion: Chocolate can be made in the form of liquid , paste or in a block or used as a flavoring agent in other foods. Chocolate manufacturing is complex and requires several technology operations and process to achieve the desired product quality. During process physical properties ,rheological properties of chocolate are influenced largely by its processing techniques ,particle size distribution and ingredient composition.