Press release NETZSCH-Feinmahltechnik GmbH Sedanstraße 70 D-95100 Selb Tel.: + 49 9287 797-0 Fax.: + 49 9287 797 149 info@nft.netzsch.com http://www.netzsch-grinding.com http://www.chocoeasy.com CHOCOEASY The Easy Way to Chocolate Do you think it is impossible to produce small quantities of high-quality chocolate to your desired flavor? NETZSCH- Feinmahltechnik GmbH presents the solution: the CHOCOEASY plant! Using standard raw materials readily available on the market, dark, milk and even white chocolate can be produced on the CHOCOEASY quickly, cost-efficiently and consistently. A broad range of machines allows production of batches from 25 to 6000 kg within the enclosed, space-saving module. Thanks to innovative technology, the process steps conching and fine grinding combined with the user-friendliness of the module guarantee high quality, and reproducible, chocolates. There are no boundaries to your imagination when developing new formulations with the CHOCOEASY. For more information please visit www.chocoeasy.com. About NETZSCH-Feinmahltechnik GmbH NETZSCH-Feinmahltechnik GmbH is one of the world s market leaders in wet grinding technology. The concentration of know-how in process engineering and the comprehensive range of products from laboratory size and production size mills up to complete production lines is unique worldwide. Custom-made mixers, kneaders or dispersers for low or high-viscosity products are available for a multitude of applications just as well as a large number of wet grinding systems for different grinding tasks even down to the nano range. For more information please visit www.netzsch-grinding.com. # # #
Chocolate CHOCOEASY
The Easy Way to Chocolate A millennium before the discovery of America by Europeans, cocoa was known to the natives as a luxury food. The name chocolate comes from the Aztec word xocóatl, from xócoc (= sour, tart, spicy) and atl (=water). However, the unsweetened cocoa preparation was not agreeable to European taste. Sweetening the beverage with honey and cane sugar solved this problem and soon cocoa products were distributed all over the world. In the mid-19 th century the solid chocolate bar was developed in England and in 1875 Daniel Peter developed a method for adding milk to the chocolate bar. Today many qualities, shapes and flavors of chocolate are available. The three basic categories for chocolates are dark, milk and white chocolate. The legal requirements for cocoa and chocolate products are delineated in the European Union according to the guideline 2000/36/EG. CHOCOEASY The plant concept CHOCOEASY of NETZSCH-Feinmahltechnik GmbH is a complete process for production of premium chocolate meeting and exceeding commercially available high quality chocolate produced using traditional methods. From the raw materials cocoa mass, cocoa butter, sugar and if necessary milk powder you can produce your own dark, milk or white chocolate. Due to the simple operation of the compact CHOCOEASY plants production capacities from 25-6000 kg per batch can be produced. You can develop own formulations, flavors, adjust the flavor during the process, adjust viscosity to meet your exact specifications. There are no limits to your fantasy. 2 www.chocoeasy.com
Your Advantages The flexible CHOCOEASY process allows you to produce standard chocolates, and is very capable for producing specialities like dietary chocolate or chocolates with other sugar types and additives. Surprise your customers with own creations. Individuality - formulations according to individual requirements are easily developed with the simple operation of the compact, enclosed CHOCOEASY plant. You have a direct influence on type, flavor and quality of the chocolate. Give your fancy full scope. CHOCOEASY compact plant type CE 50 Quality - with the CHOCOEASY process you always have reproducibility in a defined, semi-automatic process. The simple, menu controlled operation panel includes temperature control, enabling the exact adjustment of your flavor. Savings - CHOCOEASY has remarkably low energy consumption, cooling water use and space requirements (each with up to 40 % savings over traditional systems). Shorter process times for a batch by grinding and liquid conching at the same time allow more productivity from a single machine, plus the semi-automatic operation means unattended operation. This revolution in the chocolate production method may enable a saving of up to 5 % cocoa butter. Flexibility - thanks to the modular construction of the plant designed for your present requirement, future expansion of the system to increase output by adding a conche is easily accomplished. Efficiency - with the CHOCOEASY the production of small quantities of standard or special chocolates with your own touch is possible (batch sizes of 25 kg). www.chocoeasy.com 3
The CHOCOEASY Process The CHOCOEASY integrates the conventional process steps, known from classic production processes. Dry conching is the most important step for quality development of chocolate. The dry conching step runs extremely efficiently with the CHOCOEASY process. Using agitator bead mills instead of five roller mills for fine grinding (or refining) of the chocolate, the refining and liquid conching processes run at the same time. Thus, the process times are shorter and produce the same or better quality compared with chocolate from conventional plant. Pre-grinding Melting Crystal sugar and milk powder, particle size < 300 µm Cocoa mass, cocoa butter and/or max. 5 % equivalent vegetable fat Intermediate storing Intermediate storing Storage tank with horizontal agitator shaft and screw discharge Heatable mixing tank with vertical agitator shaft Dry conching Dosing Heatable conching tank with horizontal special agitator shaft Lecithin and possible vanillin Liquid conching Fine grinding Chocolate 4 www.chocoeasy.com
The Process Details Pre-grinding - the pre-grinding of crystal sugar to a particle size of < 300 µm is made on a NETZSCH CUM universal mill. The transport system from feeding station to the dry mill is completely enclosed and pressure shock resistant up to 10 bar. Melting - parallel to feeding the dry solids for pre-grinding, the cocoa butter and cocoa mass are melted. The storage tanks are equipped with an agitator shaft to maintain a good homogeneity. Dry conching - after pre-heating, the conche is fed with preground solids and a portion of the liquid components. A specially designed horizontal mixing shaft provides a thorough mixing of the ingredients. The dry conching process of the mass commences with intensive hot air supply (60-90 C) and a fat content of 15-18 %. Liquid conching - cocoa butter is added after the dry conching process. The conche is adjusted to the requested temperature. Homogenization and liquid conching of the mass follow. Depending on the requirement the formulation is completed by addition of lecithin as well as further components (e.g. vanillin) during the liquid conching. Fine grinding - wet fine refining occurs simultaneously with the liquid conching. The refining is a circulation operation on an LME agitator bead mill. This high throughput rate circulation operation provides consistent, incremental particle size reduction while maintaining a constant temperature. The key to this trouble-free operation is the patented, high efficiency grinding ball separation system. www.chocoeasy.com 5
The Quality Conching as a central process in chocolate production is essential for quality, fine taste and melting behavior of the chocolate. The process control of the CHOCOEASY plants enable the production of standard to very fine, smooth chocolate qualities. Dry conching is most important for the quality development of the chocolate. The removal of moisture, bitter aromas and flavors (acetic acid and different volatile additives) as well as the flavor development are especially effective due to the intensive air supply. As this process runs in CHOCOEASY plants with lower cocoa butter portion (15-18 % instead of 23-26 %), a faster and more effective reduction of the moisture is achieved. Dry conching process in a CHOCOEASY type CE 50 The wet fine grinding in circulation operation at the end of the process enables the adjustment of the requested qualities and fineness. The simultaneously running liquid conching and wet fine grinding lead to homogeneous products with narrow particle size distribution. This shows the comparison of chocolate from traditional production methods via five roller mill with the chocolate produced on CHOCOEASY. Liquid conching process in a CHOCOEASY type CE 50 red blue... Particle size distribution of standard production chocolate... Particle size distribution if chocolate processed on CHOCOEASY 6 www.chocoeasy.com
The Sizes Type Batch size [kg] Space requirement [m²] CHOCOEASY 50 25-50 approx. 2-4 CHOCOEASY 300 150-300 approx. 4-6 CHOCOEASY 750 375-750 approx. 40 CHOCOEASY 1500 750-1500 approx. 60 CHOCOEASY 3000 1500-3000 approx. 100 CHOCOEASY 6000 3000-6000 approx. 120 Subject to technical changes The CHOCOEASY plant can be modularly enlarged (e.g. with one more conches and mill), increasing the production capacity without great expense. CHOCOEASY compact plant type CE 300 CHOCOEASY plant type CE 3000 www.chocoeasy.com 7
Chocolate Compounds
What is What? Chocolate coatings, fatty glazes and fillings are distinguished by a higher fat content in the chocolate. Depending on the temperature they are essentially responsible for taste and viscosity, influencing the consistency, the mouth feel, flavor and melting behavior. Couverture (chocolate coating) - is a fattier chocolate mass with at least 31 % cocoa butter portion (guideline 2000/36/EG) and maximum 5 % equivalent vegetable fat (CBE). It is used in pastry shops and as chocolate coating for praline production as well as in many different chocolate containing products. The composition of the couverture can vary. Milk powder is added in milk couverture and in white couverture the cocoa mass is replaced by milk powder and a higher portion of cocoa butter and sugar. Compounds (fatty glazes) - are a more cost-effective alternative to couverture. The expensive cocoa butter can be replaced to more than 5 % by a partly mixable vegetable fat (CBR) or even by a completely different composition of non mixable vegetable fat. A softer and more elastic consistency of the coating is achieved by the melting behavior of the fats. Fillings - are an important component of many sweets. The vegetable fats form the continuous phase in which the other ingredients are embedded. Therefore the physical and chemical characteristics of the fat and the resulting factors are most important for the quality of the final product. The higher fat content and the utilization of different vegetable fats change the consistency of the mass in comparison to standard chocolate in that the production and processing become easier. Due to the elimination of cocoa butter, tempering is not applicable. The time spent for the expensive dry and liquid conching process is eliminated. 2
So it Works Pre-grinding Melting Crystal sugar and possibly milk powder Cocoa mass, cocoa butter and/or vegetable fat (CBE, CBS, CBR) Intermediate storing Intermediate storing Storage tank with horizontal agitator shaft and worm discharge Heatable mixing tank with vertical, slow running agitator shaft Mixing, Homogenization Intermediate storing Fine grinding Heatable mixing tank with vertical agitator shaft 1-pass, multi pass or circulation grinding on agitator bead mill(s) Final product 3
So it Can Look Like The complete plant for the production of couverture, fillings and fatty glazes. From feeding of the solids to pre-grinding and the following homogenization and wet grinding. Crystal sugar and possibly milk powder are fed via the powder feeding station, air-conveyed by the blower and pre-ground on the CUM universal mill. Parallel to solid pre-grinding the cocoa mass and fat components are separately melted and stored in stirred and heated agitator tanks. (not shown) Separation of the powder fraction from the mill air by the dust filter (pressure shock resistant up to 10 bar). The pre-ground sugar, and the milk powder if necessary, is dosed via the solid storage tank directly into the mixing tank which is preloaded with the fat phase and cocoa mass. After finishing the homogenization process, the mass is pumped into a second mixing tank. A further batch can be homogenized in the mixing tank. Depending on the quality requirement the mass is ground in pass or circulation operation on a horizontal disk agitator bead mill type LME. 4
Sugar Pre-Grinding Sugar forms one of the main components in the formulations for couverture, fillings and fatty glazes. Depending on the product its portion is usually between 30 % and 70 %. The higher the sugar content and the finer the sugar, the more viscous the batch mass. Sugar suitable for wet preparation can have an initial fineness of 100 µm (powdered sugar) to 1 mm (crystal sugar). The initial fineness of the sugar has a direct influence on the production capacity of the plant. Blast rotor Coarse crystal sugar should be preground. At temperatures of approx. 60-70 C there is the risk of caramelizing, therefore only grinding systems that work at low grinding temperatures can be considered for the grinding process. The CUM universal mill of NETZSCH- CONDUX Mahltechnik GmbH with blast rotor is ideal for this process. The construction of the blast rotor mill produces a high air volume that leads to lower grinding temperatures and enables a naturally aspirated mill operation. The blast rotor is driven with a peripheral speed of up to 110 m/s and equipped with exchangeable baffle plates. It is surrounded by a screen basket. The grinding process mainly occurs by impact stress. The fineness can be changed by adaptation of peripheral speed and screen design. The transport system from feeding station to the dry mill is completely enclosed and pressure shock resistant up to 10 bar. Universal mill type CUM 680 Stator - screen basket Throughput rate of CUM 300 universal mill in dependence on the fineness d 97 Type CUM 150 CUM 250 CUM 300 CUM 450 CUM 680 Scale-up Factor 0.38 0.6 1 2 4 of blast rotor [mm] 170 244 300 450 680 Speed [min -1 ] 12000 9000 7350 4600 3100 Drive power [kw] 4 11 18,5 37 75 Nominal air quantity [m 3 /h] 400 1270 1500 2850 5150 Throughput rate [kg/h] 380 600 1000 2000 4000 Subject to technical changes 5
Fine Grinding of the Batch Mass The required final fineness of chocolate coatings, fatty glazes and fillings are normally between 18 and 30 µm. Agitator bead mills that guarantee high throughput rates are used to obtain these values. Beside the efficiency of the separation system, the maximum throughput rate is also influenced by the initial particle size of the sugar. The initial sugar fineness has a direct influence of the mode of operation of the agitator bead mill, either single pass or a circulation process. With the horizontal agitator bead mill type LME NETZSCH- Feinmahltechnik GmbH offers the optimal wet grinding system for the desired grinding process. It is equipped with TriNEx grinding disks agitator shaft for triple impulse frequency and the highly efficient classifying rotor. This combination enables very high throughputs without blocking the grinding media separation system by over compression of the beads in the discharge area. The grinding chamber is of chilled cast iron or wear resistant steel. The grinding chamber inner liner can be reversed so that the lifetime of the vessel is doubled. Depending on the initial fineness of the sugar, steel grinding media with a diameter of 3 mm, 4 mm, 5 mm or 6.35 mm are used. Modes of operation Single pass operation The simplest mode of operation for batch masses with fine sugar. The mass is pumped one time from the storage tank through the agitator bead mill into a storage tank. The final quality after the single step grinding is dependent on the throughput rate, rotor speed and bead size of the agitator bead mill. Grinding disks System TriNEX Circulation operation The batch mass is pumped at extremely high flow rates from the storage tank through the agitator bead mill and back into the storage tank. A continuous quality development is obtained by this method. This mode of operation is used for batch masses with coarse or lightly pre-ground sugar. The high flow rate prevents settling of the sugar, precise particle size distribution control and optimal temperature control. Cascade operation Batch masses with sugar fineness from fine (100 µm) to coarse (1 mm) can be ground on two agitator bead mills arranged in series, providing continuous output. No stop in production is necessary if maintenance work for one mill is required. Horizontal agitator bead mill type LME 500 Type LME 30 LME 60 LME 150 LME 200 LME 300 LME 500 Grinding chamber volume (approx.) [l] 30 60 140 230 300 560 Drive power [kw] 18.5 / 22 37 / 45 55 / 75 75 / 90 90 / 110 160 / 200 Length [mm] 2000 2500 2900 2950 3600 4150 Width [mm] 1100 1400 1000 1000 1200 1360 Height [mm] 1600 1800 2200 2200 2400 2600 6 Subject to technical changes
Realization Plants from NETZSCH-Feinmahltechnik GmbH are modularly built for production of chocolate coatings, fatty glazes and fillings. The module construction minimizes the space requirement and enables a simple enlargement of production. The pre-grinding of sugar on a CUM universal mill and the storage in a horizontal storage tank with integrated screw conveyor can operate two wet preparation lines, increasing efficient use of the machinery and capital investment. The lines contain a primary homogenization of the single components in a mixing tank with high-speed dispersing tool and slow running anchor type stirrer for product circulation, pumping of the mass into the heatable storage tank and finishing with fine grinding on an LME agitator bead mill. The plant shown for fatty glazes without pre-grinding and intermediate storage of the sugar. The fine grinding of the mass for higher qualities is realized by multi pass operation i.e. two agitator bead mills type LME arranged in series. The production capacity of a plant is dependent on the size of the agitator bead mill type LME and the initial fineness of the sugar. The table below shows this interrelation. Mill type Scale-up Factor Throughput rate [kg/h] Sugar 1 mm Sugar 300 µm Sugar 200 µm Sugar 100 µm LME 4 0.25 20 30 40 60 LME 30 1 80 125 170 250 LME 60 2 150 250 340 500 LME 150 4 300 550 680 1000 LME 200 6 450 750 1000 1500 LME 300 8 650 1000 1350 2000 LME 500 12 950 1500 2000 3000 7
Cocoa
Fine Grinding of the Pre-Ground Cocoa Mass The immense popularity of Cocoa requires large quantities of finely ground cocoa mass. Production capacities from a single nib grinding system are between 1 and 5 tons per hour. Grinding mills that provide high throughputs with a guaranteed grind quality are essential for this process. The best results are obtained using agitator bead mills with approx. 100 to 500 l grinding chamber volumes. High throughput rates are reached by both the efficiency of the grinding bead separation system and the quality or fineness provided by the pre-grinding system. For very fine particle size cocoa mass, two agitator bead mills are run in series to provide high production capacity with a fineness of 99.7 % < 75 microns (sieve analysis). NETZSCH-Feinmahltechnik GmbH offers two machine designs for the production of cocoa mass. The horizontal agitator bead mill type LME is equipped with a TriNEx disk agitator shaft and a highly-efficient classifying rotor system for separation of the grinding beads. This combination enables very high throughputs without blocking the grinding media separation system by over compression of the beads in the discharge area. Generally, steel grinding media with a diameter of 4 mm, 5 mm or 6.35 mm are used. The grinding chamber is of a specially developed chilled cast iron or wear resistant steel. The grinding chamber inner liner can be reversed so that the lifetime of the vessel time is doubled. The vertical agitator bead mill type KE SK is the classic cocoa mass fine grinding mill. The KE has been successfully used for fine grinding of cocoa mass for more than 30 years. The agitator shaft is equipped with 15 eccentric disks. The grinding chamber inner liner is also of wear resistant materials. The retention of the grinding media occurs at the top of the grinding chamber by a highly wear resistant screen plate The KE is advantageous for factories with limited floor space. Series of vertical disk mills type KE 300 SK Horizontal disk mill type LME 500 Type KE 100 SK KE 300 SK Grinding chamber volume [l] 120 333 Drive power [kw] 55 90 Throughput rate [l/h] 600-1000 1500-3000 Length [mm] 2200 1800 Width [mm] 820 1200 Height [mm] 3100 4000 Subject to technical changes Type LME 30 LME 60 LME 150 LME 200 LME 300 LME 500 Grinding chamber volume (approx.) [l] 30 60 140 230 300 560 Drive power [kw] 18.5 / 22 37 / 45 55 / 75 75 / 90 90 / 110 160 / 200 Throughput rate (*) [l/h] 300-600 500-1000 800-1600 1500-3000 2000-4000 3000-6000 Length [mm] 2000 2500 2900 2950 3600 4150 Width [mm] 1100 1400 1000 1000 1200 1360 Height [mm] 1600 1800 2200 2200 2400 2600 (*) Depending on quality and mode of operation Subject to technical changes 2
Pulverization of the Cocoa Press Cake The finely ground cocoa solids are separated from the cocoa butter in a filter press resulting in liquid cocoa butter and solid cocoa press cake. The cocoa butter is filtered and stored in tanks for final use or sale in liquid or solid form. The compacted cocoa press cake is first crushed on roller mill and then finely ground to cocoa powder using an impact mill. Classifier mill type CSM 560 Depending on the fat content of the cocoa press cake NETZSCH- CONDUX Mahltechnik GmbH recommends one of two different machine types for pulverization. The CSM classifier mill is suitable for a fat content of 10 to 12 %. This mill type is distinguished by cooled induction air which provides higher throughput rates. The final product has a defined upper particle size cut-point due to the integrated classifier wheel. If the fat content of the pre-broken cocoa press cake is higher than 12 % the CUM universal mill type is recommended. The CUM is equipped with two counterrotating, pinned disks. Under certain terms a grinding on a classifier mill is also possible. Type CSM 360 CSM 560 of grinding disks [mm] 610 1044 Mill / classifier speed [min -1 ] 3650 / 3000 2100 / 2000 Mill / classifier drive power [kw] 30 / 7.5 75 / 15 Air quantity [m 3 /h] 3600 9000 Throughput rate (*) [kg/h] 800-2000 2000-5000 Universal mill type CUM 300 Classifier wheel and guide ring (*) Depending on the initial temperature, initial fineness and fat content Subject to technical changes Type CUM 300 CUM 450 CUM 680 Speed H/D [min -1 ] 8200 / 6400 5400 / 2950 3600 / 2100 Drive power H/D [kw] 22 / 15 45 / 30 90 / 55 Air quantity [m 3 /h] 1900 3900 7550 H = Housing / D = Door Subject to technical changes 3
The New Confectionery Series of the NETZSCH Business Unit Grinding & Dispersing The easy way from cocoa to complete compound mass or exquisite chocolate Service and Competence - Worldwide and Close to our Customer We offer customized solutions for your requirements State-of-the art application laboratories for processing your products are available Testing provides: - Extensive quality analysis and test recording - Intensive discussion on the results - Scale-up to your production requirements Project planning and management / Start up service / After sales support NETZSCH Feinmahltechnik GmbH Sedanstraße 70 P.O. Box 14 60 D-95088 Selb/Bavaria Telephone +49 9287 797-0 Telefax +49 9287 797 149 info@nft.netzsch.com www.netzsch-grinding.com NETZSCH-CONDUX Mahltechnik GmbH Rodenbacher Chaussee 1 D-63457 Hanau/Wolfgang Telephone +49 6181 506-01 Telefax +49 6181 571 270 info@ncx.netzsch.com www.netzsch-grinding.com Your local contact person is: info@nft.netzsch.com www.netzsch-grinding.com
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CHOCOEASY
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NETZSCH- & - CHOCOEASY,. : - - / / NETZSCH Feinmahltechnik GmbH 70 / 14 60 D-95088 / +49 9287 797-0 +49 9287 797 149 info@nft.netzsch.com www.netzsch-feinmahltechnik.de NETZSCH-CONDUX Mahltechnik GmbH 1 D-63457 / +49 6181 506-01 +49 6181 571270 info@ncx.netzsch.com www.netzsch-condux.de : info@nft.netzsch.com www.netzsch-mahlen.de