Some aspects of Chocolate and Confectionery Technology Jana Čopíková UCT, Praha, Department of carbohydrates and cereals 30.10.2015 http://www.smithsonianmag.com/arts-culture/a-brief-history-of-chocolate-21860917
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 World s Great Chocolate and Confectionery Producers in 2013 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 Candy Industry, leden 2013
Production of coca beans Theobroma cacao, rain forest tree, 10 of north latitude and 10 of south latitude Variety: Criollo: Central America; Forastero (Amelonado): Amazonas region; Trinitario hybrid
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
Fermentation Goals: Removing of pupl Prevention of germination Botanical and biological death of seeds Starting of enzymatic activity Reducing of the bitter and astringent taste Formation of precursors of chocolate Change of color
Fermentation of cocoa beans Sugars CO 2 + C 2 H 5 OH Pectin oligosaccharides Destruction of cell walls, release of juice Sucrose Glc + Fru Proteins oligopeptides, amino acids Glykosides sugars + aglycones Polyfenols chinons Ethanol and other alcohols organic acids ph
Production and export of cocoa beans
Consumption of chocolate and sugar confectionery http://www.bon-bon.cz/
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 200/36 defining the composition of chocolate Product Cocoa butter (%) Dry non-fat cocoa solids (%) Total dry solids Bitter chocolate 26 43 Milk chocolate 2,5 25 Chocolate coating 16
Composition of chocolate, viscosity and yield Content (%) Chocolate h CA (Pa s) t CAo (Pa) Fat Sucrose Lactose Moisture Bitter Max 3,0 5,0 35 49 1,5 Min 3,0 5,0 31 42 1,1 Milk Max 1,0 1,0 38 55 14 2,4 Min 1,0 1,0 28 36 7 0,7 Fat Sugars Flavanols and Proteins Energy value Methylxantins procyanidins ORAC 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
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: 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
Heat transfer -radiation Pretreatment-Micronizing 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
Heat transfer -convection -conduction Roasting of nib and (cocoa beans) Probat Neptun http://probatburns.com 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/
Milling Ball mill Stone mill (Fryma-Maschinen AG) www.fblehmann.de 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 µm particles
Conching of chocolate Milk chocolate: 24 h, 45-60 C Bitter chocolate: 48 h, 55-85 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 30-60 http://www.carle-montanari.it/
Conching of chocolate http://www.youtube.com/watch?v=chtgfpl2edu http://www.carle-montanari.it/
Tempering: Crystallization of cocoa butter (nucleation) in chocolate http://www.youtube.com/watch?v=omju9nnz_oq http://www.youtube.com/watch?v=m3r3_p5jgum http://www.aasted.eu/ http://www.sollich.com http://www.youtube.com/watch?v=bi9_mg3ozvi
Cocoa butter Crystal form Nomeclatu re (Loisel a kol. 1998) Crystal form (Dimick 1991) Melting poit ( C) (Kattenberg 2001) Latent enthalpy of heating(kj/g) (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 Sources of cocoa butter equivalents: shea, ilipé, mango kernel, kokum gurmi
content of crystals (%) content of crystals (%) Pseudo-phase diagrams of mixture of two substances: Cocoa butter and Equivalent Cocoa butter and Replacer Equivalent Cocoa butter Replacer Cocoa butter
Moulding, forming, enrobing http://www.youtube.com/watch?v=dhuwho05meu http://www.aasted.eu/ http://www.youtube.com/watch?v=ercrug64bli http://www.youtube.com/watch?v=y4ykqx-hamc
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
Sugar confectionery Amorphous sugars hard candies, jellies, caramels (toffee) Crystallized sugars - fondant, lozenges, nougat, marzipan, caramels (fudge)
Flow chart of hard candy 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
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 candy and fondant Hard candy 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 candy Glassy state amorphous sugars Crystals in deteriorated 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.
b.v. ( C) Trends of the boiling point as the mass fraction of components 220 210 200 190 180 170 160 150 140 130 120 110 100 60 65 70 75 80 85 90 95 100 105 S hmotnostní Mass fraction zlomek x (%) x (%) Vacuum 36 D.E. 64 D.E. 43 D.E. Sacharosa Sucrose
Batch cooker Heat transfer -conduction Heat exchanger Steam in the jacket https://www.hosokawa-bepex.com/
Moulding of confectionery mass
Forming of hard candy https://www.youtube.com/watch?v=yl_hw6keiww http://www.youtube.com/watch?v=bmx8rn2p528 http://www.youtube.com/watch?v=2lerf1zgrde
Crystallization of fondant
http://nid.com.au Moulding in starch trays
Confectionery jelly Arabic gum Starch Gelatine Agar Pectin Content (%) 35-45 9-12 5-12,5 1-1,5 1-1,5 Temperature 1 ( o C) Temperature 2 ( o C) Temperature 3 ( o C) Temperature 4 ( o C) 25 71-82 60-65 87-95 93-100 82 93 71-82 76 93 71-82 82-93 71-72 65-76 82-93 20-37 20-37 20-37 35-37 71-82 Time 4 (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
Questions?