Engineering Problem Solving I 59:005, The University of Iowa

Guilt-Free Chocolate...

Chocolate Manufacturing

and

Food Processing

Engineering Problem Solving I 59:005, The University of Iowa

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

Engineering Problem Solving I 59:005, The University of Iowa

Learning about Chocolate

History of Chocolate Economics of Chocolate Engineering of

Chocolate

EPSI: Chocolate Cookie Project

www.chocolateandcocoa.org

Engineering Problem Solving I 59:005, The University of Iowa

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

Engineering Problem Solving I 59:005, The University of Iowa

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

M&M/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

Engineering Problem Solving I 59:005, The University of Iowa

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

Engineering Problem Solving I 59:005, The University of Iowa

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

Engineering Problem Solving I 59:005, The University of Iowa

Cocoa Producing Countries

Barry Callebaut, USA Inc. 2002

Near the equator, high T and high humidity

Engineering Problem Solving I 59:005, The University of Iowa

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

Engineering Problem Solving I 59:005, The University of Iowa

Chocolate Consumers

Barry Callebaut, USA Inc. 2002

Engineering Problem Solving I 59:005, The University of Iowa

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

Engineering Problem Solving I 59:005, The University of Iowa

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

QuickTime™ and aTIFF (Uncompressed) decompressorare needed to see this picture.

Barry Callebaut, USA Inc. 2002

Engineering Problem Solving I 59:005, The University of Iowa

Economics of Cocoa

http://www.candyusa.org/CocoaTree/sustain.htm

Small Farms -- 90% of world cocoa on 5-10 acre farms

Market price impacts plant quality Challenges with pests and disease impact market.

Engineering Problem Solving I 59:005, The University of Iowa

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/supplyindex.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_prices.htm

Engineering Problem Solving I 59:005, The University of Iowa

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.

Engineering Problem Solving I 59:005, The University of Iowa

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.”

Engineering Problem Solving I 59:005, The University of Iowa

Chocolate Manufacturing

and

Food Processing

Guilt-Free Chocolate... From Bean to Bar

Engineering Problem Solving I 59:005, The University of Iowa

“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

Engineering Problem Solving I 59:005, The University of Iowa

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

Engineering Problem Solving I 59:005, The University of Iowa

Brainstorm

List food-handling considerations in your home?

How might these principles be implemented on an industrial scale?

Engineering Problem Solving I 59:005, The University of Iowa http://www.gmp1st.com/gmp.htm

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.

Good Manufacturing Practices

Engineering Problem Solving I 59:005, The University of Iowa

Elements of GMP

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

Engineering Problem Solving I 59:005, The University of Iowa

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”

Engineering Problem Solving I 59:005, The University of Iowa

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.”

Engineering Problem Solving I 59:005, The University of Iowa

Coating Cookies with Chocolate

EPSI Team Project

http://www.wilburchocolate.com/docs/applications/bakery/chocolate_coatings.html

Engineering Problem Solving I 59:005, The University of Iowa

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.

Engineering Problem Solving I 59:005, The University of Iowa

Available equipment and supplies

Cookies, chocolate chips, chocolate almond bark

Bowls, trays, wax paper, and kitchen utensils

Microwaves Kitchen scales and calipers Refrigerator

Engineering Problem Solving I 59:005, The University of Iowa

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