Some aspects of Chocolate and Confectionery Technology. Jana Čopíková

Transcription

1 Some aspects of Chocolate and Confectionery Technology Jana Čopíková Erasmus,

2 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

3 The World s Great Chocolate and Confectionery Producers in 2012 Producer Total sale 2012 (USD mil) Mars Inc (USA) Mondeléz International Inc (USA) Barcel SA, divison of Grupo Bimbo (Mexico) * Nestlé SA (Switzerland) Meji Co Ltd (Japan) * Hershey Foods Corp (USA) Ferrero Group (Italy) Chocolatefabriken Lindt&Sprüngli AG (Switzerland) August Storck KG (Germany) Yildiz Holding (Turkey) Candy Industry, leden 2013

4 Chocolate and chocolate confectionery Production of coca beans Theobroma cacao, rain forest tree, 10 of north latitude and 10 of south latitude

5 Grinding of cocoa beans Consumption of chocolate a chocolate confectionery , Switzerland Norway Belgium Germany Irland GB Austria Denmark Finland EU 15 countries USA Czech Republic France 5,1 Australia The Netherland Sweeden Canada Italy Greece Portugal Japony 2,0 Spain Brazil

6 Production and export of cocoa beans

7 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

8 Composition of chocolate, viscosity and yield Chocolate η CA τ CAo Content (%) (Pa s) (Pa) fat sucrose lactose moisture bitter max. 3,0 5, ,5 min ,1 milk max ,4 min. 1,0 1, ,7

9 Legislation of chocolate and applying of the cocoa butter equivalent EU Directive 2000/36/EC 23th June The applying of non-cocoa vegetable fats was allowed, 5% of total content. EC Directive defining the composition of chocolate and chocolate products

10 Chocolate and Nutrition Fat Sugars Flavanols and Proteins Energy value Methylxantins procyanidins ORAC g/100 g kj/100 g mg/100 g * Chocolate ,1 Red wine ,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 NH 2 Anandamide (N-arachidonoylethanolamide) Magnesium, Mg (600 mg/100 g) Anthocyan 2 Fenylethylamine (max 0,6 mg/100 g)

11 Flow sheet of cocoa liquor and cocoa powder Cocoa liquor Fermented cocoa beans Pretreatment Grinding Nibs of cotyledons Winnowing Nibs roasting Cocoa butter alkalisation Shell, sprouts) Pressing Pressed cake Grinding Pulverizing Cooling Stabilization Milling Packaging Cocoa liquor Cocoa powder Cocoa powder: % cocoa butter, % cocoa butter

12 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

13 Heat transfer -radiation Pretreatment-Micronizing Infrared treatment plant IR

14 Grinding + winnowing Winnower - Types: HEA 150 / HEA 200 Winnowing Plant 90 (Petzholdt Heidenauer) Crushing of cocoa beans and separating of pulp, hulls and germs

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

16 Milling Ball mill Stone mill (Fryma-Maschinen AG) Mixing of chocolate mass Static mixer

17 Refining Chocolate Refiner-Buhler SFL 1300 Roll mills Carle-Montanari Refining of mass and change from plastic to pulverous state,rolles are cooled at C, speed is increasing up, result - 20 µm particles

18 Conching of chocolate Milk chocolate: 24 h, C Bitter chocolate: 48 h, C Phases: dry conching (6-12 h) Results: liquid conching (10 h) + CB or CBE homogenization + emulsiphier Complete homogenization Reducing of viscosity Reducing of content of low volatile organic acids and water Creation of typical chocolate aroma Conche Carle-Montanari Clover

19 Tempering: Crystallization of cocoa butter (nucleation) in chocolate 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

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

21 Cocoa butter 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 ,4 118 V β 2-3 triklinic 30,7 137 VI β ,8 148

22 Butyrospermum parkii Equatorial Africa, shea, Mali, Cameroon, Congo, Côte d'ivoire, Ghana, Guinea, Togo, Nigeria, Senegal, Sudan, Burkina Faso and Uganda.

23 Madhuca longifolia illipé, India Indie : Jharkhand, Uttar Pradesh, Bihar, Madhya Pradesh, Kerala, Gujarat and Orissa

24 Moulding, forming, enrobing

25 Cooling Heat transfer via radiation, product leaves the cooling tunnel under the dew point. Remoulding and package

26 Cocoa powder flow sheet Cocoa liquor Pressing Pressed cake Grinding Pulverizing Cooling Stabilization Packaging Cocoa powder

27 Cocoa powder

28 Flow sheet of compounds Cocoa powder, Sucrose, Cocoa butter replacers or substitudes Mixing Milling Forming, moulding Cooling Demoulding Package Compound

29 Compounds - Milling Impact mill Ball-mill

30 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

31 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 S or P H C O or L H 2 C S or P Eur Food Res Technol (2006) 222: , Aleksandra Torbica Olga Jovanovic Biljana Pajin

32 Pseudo-phase diagrams of mixture of two substances: Cocoa butter and Equivalent Cocoa butter and Replacer content of crystals (%) content of crystals (%) Equivalent Cocoa butter Replacer Cocoa butter

33 1. Rheology: Determination of viscosity η CA and yield stress τ 0CA Casson viscosity η CA shear stress mass flows contiously Casson yield stress τ 0CA shear stress mass starts to flow Rotational Rheometer Chocolate τ 0CA = Pa η CA = 1-20 Pas Shear stress Newton liquids linear relationship between shear stress and viscosity: dv τ =η dy Nenewton liquids linear relationship according to Casson equation : τ τ = η. 0 dv dy

34 2. Determination of particle size/ Stanovení velikosti částic Particle size in chocolate 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

35 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 MQC

36 4. Determination of carbohydrates by HPLC

37 Determination of all components Near infrared spectroscopy calibration models 1,2 1,0 0,8 Absorbance 0,6 0,4 0,2 0, Wave number (cm -1 ) Near infrared spectra of cocoa powder

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

39 Flow chart of hard candies technology sucrose, water, glucose syrup sucrose + water glucose syrup dissolving mixing mixing evaporation cooling dyeing and flavours forming wrapping acids, colours, flavour dissolving evaporation dyeing and flavours moulding cooling demoulding wrapping

40 Flow chart of fondant technology sucrose, water, glucose syrup mixing dissolving evaporation whipping moulding into starch crystalization of sucrose demoulding wrapping

41 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

42 Hard candies and fondant Hard candies Mass ratio of glucose syrup and sucrose 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 kg : 100 kg Water activity , i.e. fondant has tendency to be dried The content of dry matter 80 % Glucose syrup has dry matter 80 %

43 Hard candies Glassy state amorphous sugars Crystals in amorphous mass

44 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

45 Dissolution of components and Heat transfer evaporation - convection (jet cooker), - conduction (tube heat-exchanger and batch cooker), - radiation.

46 Solubility and boiling point of sucrose solutions 1 solubility of sucrose, 2 boiling point of sucrose solutions

47 Trends of the boiling point as the mass fraction of components b.v. ( C) S hmotnostní Mass fraction zlomek x (%) x (%) Vacuum 36 D.E. 64 D.E. 43 D.E. Sacharosa Sucrose

48 Batch evaporator Heat transfer -conduction

49 Moulding of confectionery mass

50 Forming of hard candies

51 Crystallization of fondant

52 Moulding in starch

53 Confectionery jelly Arabic gum Starch Gelatine Agar Pectin Content (%) ,5 1-1,5 1-1,5 Temperature 1 ( o C) Temperature 2 ( o C) Temperature 3 ( o C) Temperature 4 ( o C) Time 4 (h) Moisture of starch (%) Notes: 1 Temperature of dissolving, 2 Temperature of acid, 3 Temperature of moulding, 4 Temperature and time of setting

54 Questions?