Some aspects of Chocolate and Confectionery Technology

Jana Čopíková

Erasmus, 11.3.2013

Content

1) World production of cocoa beans, production and consumption of chocolate including cocoa powder 2) Technology of chocolate, cocoa powder and compounds - Flow chart a,b) 3) Sugar confectionery

http://www.icco.org/ http://www.caobisco.com

Producer Total sale 2012 (USD mil)

Mars Inc (USA) 16 800 Mondeléz International Inc (USA) 15 480 Barcel SA, divison of Grupo Bimbo (Mexico) 14 095* Nestlé SA (Switzerland) 12 808 Meji Co Ltd (Japan) 12 428* Hershey Foods Corp (USA) 6 480 Ferrero Group (Italy) 5 627 Chocolatefabriken Lindt&Sprüngli AG (Switzerland) 2 791 August Storck KG (Germany) 2 272 Yildiz Holding (Turkey) 2 200

The World’s Great Chocolate and Confectionery Producers in 2012

Candy Industry, leden 2013

Chocolate and chocolate confectionery

Theobroma cacao, rain forest tree, 10 °of north latitude and 10 °of south latitude

Production of coca beans

0

2

4

6

8

10

12

Switzerl

and

Norway

Belgium

German

yIrla

nd GB

Austria

Denmark

Finland

EU 15 co

untries USA

Czech

Rep

ublic

France

Australi

a

The N

etherl

and

Sweede

n

Canad

aIta

ly

Greece

Portuga

l

Japo

nySpain

Brazil

5,1

2,0

10,2

Grinding of cocoa beans

Consumption of chocolate a chocolate confectionery

Production and export of cocoa beans

Fermentation of cocoa beans

1. Anaerobic processes - ethanolic fermentation

2. Aerobic processes – lactic fermentation

acetic fermentation

Colour and flavour of cocoa beans

Drying of fermented cocoa beans → colour, flavour

Sunshine, dryers

Composition of chocolate, viscosity and yield

Chocolate

ηCA

τCAo

Content (%)

(Pa·s)

(Pa)

fat

sucrose

lactose

moisture

bitter

max.

3,0

5,0

35

49

-

1,5

min.

31

42

-

1,1 milk

max.

38

55

14

2,4

min.

1,0

1,0

28

36

7

0,7

Legislation of chocolate and applying of the cocoa butter equivalent

EU Directive 2000/36/EC 23th June 2001 - The applying of non-cocoa vegetable fats was allowed, 5% of total content.

EC Directive defining the composition of chocolate and chocolate products

Chocolate and Nutrition

NH2

O

O N

NH N

N

O

O N

N N

N

Theobromine Caffeine

2 –Fenylethylamine (max 0,6 mg/100 g)

Anandamide (N-arachidonoylethanolamide)

Magnesium, Mg (600 mg/100 g)

Epicachetine Procyanidine B2

Anthocyan

Fat Sugars Proteins Energy value MethylxantinsFlavanols and procyanidins

ORAC

kJ/100 g *Chocolate 33 45 6 2454 500 170 13,1Red wine 220 22 0,7Coffee 1200Bread 1130

* mmol Trolox equivalents/100 g

g/100 g mg/100 g

Cocoa liquor

Shell, sprouts)

alkalisation

Cocoa powder

Nibs of cotyledons

Fermented cocoa beans

Milling

Nibs roasting

Grinding

Winnowing

Flow sheet of cocoa liquor and cocoa powder

Cocoa powder: 10-12 % cocoa butter, 20- 24 % cocoa butter

Pretreatment Cocoa butter

Stabilization

Cooling

Pressed cake

Cocoa liquor

Pulverizing

Packaging

Pressing

Grinding

Flow sheet of bitter chocolate

Chocolate

Cocoa butter, CB equivalents

Chocolate mass

Cocoa liquor + Cocoa butter + Sucrose

Forming, moulding

Tempering

Refining

Conching

Mixing

Cooling

Demoulding

Package

http://www.gw-barth.de

Pretreatment-Micronizing

Infrared treatment plant IR 4000

Heat transfer -radiation

Crushing of cocoa beans and separating of pulp, hulls and germs

Grinding + winnowing

Winnowing Plant 90 (Petzholdt Heidenauer) Winnower - Types: HEA 150 / HEA 200

1, 2- imput of cocoa beans or cocoa nib, 3- preheating zone of cocoa beans or cocoa nib, 4- roasting zone of cocoa beans, 5- cooling zone of cocoa beans or cocoa nib, 6- output of cocoa product, 7- filter of air, 8- heat exchanger, 9 – cyclon; temperature of product inside 105 °C http://www.fblehmann.de/

Roasting of nib and (cocoa beans)

Heat transfer -convection -conduction

Probat Neptun http://probatburns.com

Milling

Stone mill (Fryma-Maschinen AG) www.fblehmann.de http://66.113.204.26/mining/ballmill.htm

Mixing of chocolate mass

Static mixer

Ball mill

Refining

Refining of mass and change from plastic to pulverous state,rolles are cooled at 30-45 °C, speed is increasing up, result - 20 µm particles

Roll mills

Chocolate Refiner-Buhler SFL 1300

Carle-Montanari

Conche Carle-Montanari

Milk chocolate: 24 h, 45-60° C

Bitter chocolate: 48 h, 55-85° C

Phases: dry conching (6-12 h)

liquid conching (10 h) + CB or CBE

homogenization + emulsiphier

Results:

Complete homogenization

Reducing of viscosity

Reducing of content of low volatile organic acids and water

Creation of typical chocolate aroma

Conching of chocolate

http://www.carle-montanari.it/

Clover 30-60

Temper machine Turbotemper TC·B 1- zone of melting of coca butter crystals, 2 – cooling zone, 3 – crystallization of cocoa butter, 4 – zone of temperature 31 °C, melting of unstabile crystals of cocoa butter

http://www.sollich.com/

Tempering: Crystallization of cocoa butter (nucleation) in chocolate

http://www.aasted.eu/

Sources of cocoa butter equivalents: shea, ilipé, mango kernel, kokum gurmi

http://www.cargillcocoachocolate.com/index.shtml

Crystal form Nomeclature (Loisel a kol.

1998)

Crystal form (Dimick 1991)

Melting poit (°C) (Kattenberg 2001)

Latent enthalpy of heating(kJ/g)

(Kattenberg 2001)

I β´3 (sub α)(γ) 13,1

II α-2 hexagonal 17,7 86 III β´

2-2 ortorombic 22,4 113 IV β´

1-2 26,4 118 V β2-3 triklinic 30,7 137 VI β1-3 33,8 148

Cocoa butter

Butyrospermum parkii – Equatorial Africa, shea,

http://en.wikipedia.org/wiki/Butyrospermum_parkii

Mali, Cameroon, Congo, Côte d'Ivoire, Ghana, Guinea, Togo, Nigeria, Senegal, Sudan, Burkina Faso and Uganda.

Madhuca longifolia – illipé, India

http://en.wikipedia.org/wiki/Mahua

Indie : Jharkhand, Uttar Pradesh, Bihar, Madhya Pradesh, Kerala, Gujarat and Orissa

Moulding, forming, enrobing

http://www.aasted.eu/

http://www.youtube.com/watch?v=eRCrUg64BLI

http://www.youtube.com/watch?v=dqGKp6C27Wc

Heat transfer via radiation, product leaves the cooling tunnel under the dew point.

Cooling

Remoulding and package

Cocoa liquor

Pressing

Grinding

Pulverizing

Pressed cake

Cooling

Stabilization

Packaging

Cocoa powder

Cocoa powder – flow sheet

Cocoa powder

Flow sheet of compounds Cocoa powder, Sucrose, Cocoa butter replacers or substitudes

Forming, moulding

Milling

Mixing

Cooling

Demoulding

Package

Compound

http://www.loynds.com

http://www.macintyre.co.uk

Compounds - Milling

Ball-mill

Impact mill

Analysis of chocolate

1. Rheology: Determination of viscosity and yield stress

2. Determination of particles size

3. Determination of fat

4. Determination of carbohydrates

5. Special analysis: metals, mycotoxins, pollutants

• Cocoa butter equivalent - Non-cocoa vegetable fat, type equivalent, has the same composition like CB, non lauric. Equivalent CB (CBe) is produced only by process of rafinement and/or fractionation of raw material as illepe, shea, palm oil, sal, kokum gurki and mango kernels fat. CBe is fully miscible or nearly fully miscible with cocoa butter. Chocolate mass needs tempering. Cocoa butter replacer (CBr) or cocoa butter substitute CBs - The types of non-cocoa vegetable fats are miscible with cocoa butter with some limitation. They are produced from different type of raw materials (rape seed, soya, lauric fats). Chemical processing, hydrogenation and interesterification, is allowed. CBs contains lauric acid. Mass does not need tempering.

H 2 C

H C

S or P

O or L

H 2 C S or P

http://www.aak.com/?aak=home

http://www.springerlink.com/content/34550k31r5356712/fulltext.pdf, Eur Food Res Technol (2006) 222: 385–391, Aleksandra Torbica · Olga Jovanovic · Biljana Pajin

Pseudo-phase diagrams of mixture of two substances: Cocoa butter and Equivalent Cocoa butter and Replacer

con

tent

of c

ryst

als

(%)

cont

ent o

f cry

stal

s (%

) EquivalentCocoa butter

ReplacerCocoa butter

1. Rheology: Determination of viscosity ηCA and yield stress τ0CA

Casson viscosity ηCA→ shear stress →mass flows contiously Casson yield stress τ0CA → shear stress → mass starts to flow

Newton liquids – linear relationship between shear stress and viscosity:

Nenewton liquids – linear relationship according to Casson equation :

τ0CA = 10 - 200 Pa ηCA = 1 - 20 Pas http://www.malvern.com

Chocolate Rotational Rheometer

Shear stress

dydvητ =

dydv.0 ∞

=− ηττ

2. Determination of particle size/ Stanovení velikosti částic

Particle size in chocolate 20-25 µm

a) Micrometer

b) Laser Diffraction Particle Size : The technique of laser diffraction -particles passing through a laser beam will scatter light at an angle that is related to their size

http://www.malvern.com

3. Determination of total fat content in chocolate and other cocoa derivatives

a) Soxhlet extraction – organic solvents, time consuming

b) Low resolution Nuclear magnetic Resonance (NMR), measurements

of protons in liquid phase, 50 °C

http://www.oxford-instruments.com

MQC

http://www.cyberlipid.org/extract/extr0010.htm

4. Determination of carbohydrates by HPLC

http://www.home.agilent.com/

2500 2000 1500 1000 500

0,0

0,2

0,4

0,6

0,8

1,0

1,2

Abso

rban

ce

Wave number (cm-1)

Determination of all components

Near infrared spectroscopy – calibration models

Near infrared spectra of cocoa powder

Sugar confectionery

11.3.2013

Amorphous sugars – hard candies, jellies, caramels (toffee) Crystallised sugars - fondant, lozenges, nougat, marzipan, caramels (fudge)

Flow chart of hard candies technology sucrose + water

dissolving

glucose syrup

acids, colours, flavour

wrapping

mixing

evaporation

cooling

dyeing and flavours

forming

sucrose, water, glucose syrup

mixing

evaporation

cooling

wrapping

dissolving

moulding

demoulding

dyeing and flavours

Flow chart of fondant technology sucrose, water, glucose syrup

mixing

evaporation

crystalization of sucrose

wrapping

dissolving

moulding into starch

demoulding

whipping

The role of gucose syrup in hard candies -Increasing the viscosity -Inhibition of sucrose crystalization – hard candies are in the glassy state -Bulking agent -Releasing the flavour

The role of gucose syrup in fondant - Bulking agent

Hard candies and fondant

• Hard candies • Mass ratio of glucose syrup and sucrose 50-60 kg : 100 kg • Water activity – 0.3, i.e. hard cadies are hygroscopic • The content of dry matter 98 %

• Fondant • Mass ratio of glucose syrup and sucrose 15-25 kg : 100 kg • Water activity – 0.7-0.75, i.e. fondant has tendency to be dried • The content of dry matter 80 %

• Glucose syrup has dry matter 80 %

Hard candies Glassy state – amorphous sugars

Crystals in amorphous mass

Components in formulation of hard candies

• Sucrose, glucose or maltose syrups • Isomalt • Isomalt a maltitol syrup • Glucitol • Glucitol a maltitol syrup • Maltitol • Maltitol and maltitol syrup • Lactitol • Lactitol a maltitol syrup • Content of sugars in formulation

Dissolution of components and evaporation

• Heat transfer - convection (jet cooker), - conduction (tube heat-exchanger and batch

cooker), - radiation.

Solubility and boiling point of sucrose solutions

1 – solubility of sucrose, 2 – boiling point of sucrose solutions

Trends of the boiling point as the mass fraction of components

100110120130140150160170180190200210220

60 65 70 75 80 85 90 95 100 105

hmotnostní zlomek x (%)

b.v.

(°C

) 36 D.E.64 D.E.43 D.E.SacharosaS

Mass fraction x (%)

Sucrose

Vacuum

http://www.bepexhosokawa.com/02confectionery/profile/profile.htm

Batch evaporator

Heat transfer -conduction

Moulding of confectionery mass

Forming of hard candies

Crystallization of fondant

http://nca.files.cmsplus.com/ResidentCourse/Week2/ResCourseWk2CH3AFondant&Cream.pdf

Moulding in starch

http://nid.com.au

Arabic gum Starch Gelatine Agar Pectin

Content (%) 35-45 9-12 5-12,5 1-1,5 1-1,5

Temperature1 (oC)

25 71-82 60-65 87-95 93-100

Temperature 2 (oC)

82 93 71-82 76 93

Temperature 3 (oC)

71-82 82-93 71-72 65-76 82-93

Temperature4 (oC)

20-37 20-37 20-37 35-37 71-82

Time4 (h) 24 12 4 3 1

Moisture of starch (%)

5 - 8 5 - 8 5 - 8 5 - 8 5 - 10

Notes: 1 – Temperature of dissolving, 2 – Temperature of acid, 3 – Temperature of moulding, 4 – Temperature and time of setting

Confectionery jelly

Questions?