Some aspects of Chocolate and

Confectionery Technology

Jana opkov

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
 The Worlds Great Chocolate and Confectionery Producers in 2012

Producer Total sale 2012

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

Candy Industry, leden 2013

 Chocolate and chocolate confectionery
Production of coca beans

Theobroma cacao, rain forest tree, 10 of north latitude and 10 of south latitude
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Grinding of cocoa beans

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Consumption of chocolate

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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

Sunshine, dryers

Drying of fermented cocoa beans colour, flavour

 Composition of chocolate, viscosity and yield

Chocolate CA CAo Content (%)

(Pas) (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
Flavanols and
Fat Sugars Proteins Energy value Methylxantins ORAC
procyanidins
g/100 g kJ/100 g mg/100 g *
Chocolate 33 45 6 2454 500 170 13,1
Red wine 220 22 0,7
Coffee 1200
Bread 1130
* mmol Trolox equivalents/100 g

O O

HN N N
N

O N N O N N

Theobromine Caffeine Epicachetine Procyanidine B2

NH2

Anandamide (N-arachidonoylethanolamide) 2 Fenylethylamine

(max 0,6 mg/100 g)
Magnesium, Mg (600 mg/100 g) Anthocyan
Flow sheet of cocoa liquor and cocoa powder
Cocoa liquor

Fermented cocoa beans Pressing

Pretreatment Pressed cake

Cocoa butter

Grinding Grinding
alkalisation
Nibs of cotyledons Pulverizing

Winnowing Shell, sprouts) Cooling

Nibs roasting Stabilization

Milling Packaging

Cocoa liquor Cocoa powder

Cocoa powder: 10-12 % cocoa butter,
20- 24 % cocoa butter
 Flow sheet of bitter chocolate
Cocoa liquor + Cocoa butter + Sucrose

Mixing

Chocolate mass

Refining

Cocoa butter, CB equivalents Conching

Tempering

Forming, moulding

Cooling

Demoulding

Package

Chocolate
 Pretreatment-Micronizing
Heat transfer
-radiation

Infrared treatment plant IR 4000

http://www.gw-barth.de
 Grinding + winnowing

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

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

 Roasting of nib and (cocoa beans)
Heat transfer
-convection
-conduction

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/
Probat Neptun
http://probatburns.com
 Milling

Ball mill

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

Mixing of chocolate mass

Static mixer
 Refining

Chocolate Refiner-Buhler SFL 1300

Roll mills Carle-Montanari

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

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

Conche Carle-Montanari Clover 30-60

http://www.carle-montanari.it/
 Tempering: Crystallization of cocoa butter (nucleation)
in chocolate

Temper machine Turbotemper TCB

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/ http://www.aasted.eu/
Sources of cocoa butter equivalents:

shea, ilip, mango kernel, kokum gurmi

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

Crystal form Nomeclature Crystal form Melting poit (C) Latent enthalpy of
(Loisel a kol. (Dimick 1991) (Kattenberg 2001) heating(kJ/g)
1998) (Kattenberg 2001)

I 3 (sub )() 13,1

II -2 hexagonal 17,7 86
III 2-2 ortorombic 22,4 113
IV 1-2 26,4 118
V 2-3 triklinic 30,7 137
VI 1-3 33,8 148
 Butyrospermum parkii Equatorial Africa, shea,

Mali, Cameroon, Congo, Cte d'Ivoire, Ghana,

Guinea, Togo, Nigeria, Senegal, Sudan, Burkina
Faso and Uganda.
http://en.wikipedia.org/wiki/Butyrospermum_parkii
Madhuca longifolia illip, India

Indie : Jharkhand, Uttar Pradesh,

Bihar, Madhya Pradesh, Kerala,
Gujarat and Orissa

http://en.wikipedia.org/wiki/Mahua
 Moulding, forming, enrobing

http://www.aasted.eu/

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

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

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

Remoulding and package

Cocoa powder flow sheet
Cocoa liquor

Pressing

Pressed cake

Grinding

Pulverizing

Cooling

Stabilization

Packaging

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

Mixing

Milling

Forming, moulding

Cooling

Demoulding

Package

Compound
 Compounds - Milling

Impact mill
http://www.macintyre.co.uk

Ball-mill

http://www.loynds.com
 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.

H2 C S or P

HC O or L

H2 C S or P

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

http://www.springerlink.com/content/34550k31r5356712/fulltext.pdf, Eur Food Res Technol (2006) 222: 385391, Aleksandra Torbica Olga Jovanovic Biljana Pajin
 Pseudo-phase diagrams of mixture of two
substances:
Cocoa butter and Equivalent
Cocoa butter and Replacer

content of crystals (%)

content of crystals (%)

Equivalent Replacer
Cocoa Cocoa
butter butter
1. Rheology: Determination of viscosity CA and yield stress 0CA

Casson viscosity CA shear stress mass flows contiously

Casson yield stress 0CA shear stress mass starts to flow

Shear stress
Rotational
Rheometer Chocolate
0CA = 10 - 200 Pa
http://www.malvern.com CA = 1 - 20 Pas

Newton liquids linear relationship between shear stress and viscosity:

dv
=
dy

Nenewton liquids linear relationship according to Casson equation :

dv
= .
0
dy
2. Determination of particle size/ Stanoven velikosti stic
Particle size in chocolate 20-25 m

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

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

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

of protons in liquid phase, 50 C

MQC

http://www.oxford-instruments.com
4. Determination of carbohydrates by HPLC

/
http://www.home.agilent.com
 Determination of all components

Near infrared spectroscopy calibration models

1,2

1,0

0,8
Absorbance

0,6

0,4

0,2

0,0

2500 2000 1500 1000 500

Wave number (cm-1)

Near infrared spectra of cocoa powder

 Sugar confectionery
Amorphous sugars hard candies, jellies, caramels (toffee)

Crystallised sugars - fondant, lozenges, nougat, marzipan,

caramels (fudge)

11.3.2013
 Flow chart of hard candies technology
sucrose, water, glucose syrup
sucrose + water glucose syrup

dissolving mixing

dissolving
mixing

evaporation
evaporation

acids, colours, flavour dyeing and flavours

cooling

moulding
dyeing and flavours

cooling
forming
demoulding
wrapping

wrapping
Flow chart of fondant technology
sucrose, water, glucose syrup

mixing

dissolving

evaporation

whipping

moulding into starch

crystalization of sucrose

demoulding

wrapping
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

220
210
200
190
180 36 D.E.
b.v. (C)

170 64 D.E.
160
150 43 D.E.
140 S Sucrose
Sacharosa
130
120
110 Vacuum
100
60 65 70 75 80 85 90 95 100 105
hmotnostn zlomek
Mass fraction x (%)
x (%)
 Batch evaporator

Heat transfer
-conduction

http://www.bepexhosokawa.com/02confectionery/profile/profile.htm
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
 Confectionery jelly
Arabic gum Starch Gelatine Agar Pectin

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

Temperature1 25 71-82 60-65 87-95 93-100
(oC)
Temperature 2 82 93 71-82 76 93
(oC)
Temperature 3 71-82 82-93 71-72 65-76 82-93
(oC)
Temperature4 20-37 20-37 20-37 35-37 71-82
(oC)
Time4 (h) 24 12 4 3 1
Moisture of 5-8 5-8 5-8 5-8 5 - 10
starch (%)

Notes: 1 Temperature of dissolving, 2 Temperature of acid, 3

Temperature of moulding, 4 Temperature and time of setting
Questions?