erasmus chocolate 2013
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Some aspects of Chocolate and Confectionery Technology
Jana opkov
Erasmus, 11.3.2013
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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
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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
The Worlds Great Chocolate and Confectionery Producers in 2012
Candy Industry, leden 2013
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Chocolate and chocolate confectionery
Theobroma cacao, rain forest tree, 10 of north latitude and 10 of south latitude
Production of coca beans
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02
4
6
8
10
12
Switz
erlan
d
Norw
ay
Belgi
um
Germ
anyIrla
nd GB
Austr
ia
Denm
ark
Finlan
d
EU 15
coun
tries US
A
Czec
h Rep
ublic
Fran
ce
Austr
alia
The N
etherl
and
Swee
den
Cana
da Italy
Gree
ce
Portu
gal
Japo
nySp
ainBr
azil
5,1
2,0
10,2
Grinding of cocoa beans
Consumption of chocolate a chocolate confectionery
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Production and export of cocoa beans
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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
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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
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1,1 milk
max.
38
55
14
2,4
min.
1,0
1,0
28
36
7
0,7
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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
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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
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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
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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
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http://www.gw-barth.de
Pretreatment-Micronizing
Infrared treatment plant IR 4000
Heat transfer -radiation
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Crushing of cocoa beans and separating of pulp, hulls and germs
Grinding + winnowing
Winnowing Plant 90 (Petzholdt Heidenauer) Winnower - Types: HEA 150 / HEA 200
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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
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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
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Refining
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
Roll mills
Chocolate Refiner-Buhler SFL 1300
Carle-Montanari
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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
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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/
Tempering: Crystallization of cocoa butter (nucleation) in chocolate
http://www.aasted.eu/
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Sources of cocoa butter equivalents: shea, ilip, mango kernel, kokum gurmi
http://www.cargillcocoachocolate.com/index.shtml
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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 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
Cocoa butter
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Butyrospermum parkii Equatorial Africa, shea,
http://en.wikipedia.org/wiki/Butyrospermum_parkii
Mali, Cameroon, Congo, Cte d'Ivoire, Ghana, Guinea, Togo, Nigeria, Senegal, Sudan, Burkina Faso and Uganda.
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Madhuca longifolia illip, India
http://en.wikipedia.org/wiki/Mahua
Indie : Jharkhand, Uttar Pradesh, Bihar, Madhya Pradesh, Kerala, Gujarat and Orissa
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Moulding, forming, enrobing
http://www.aasted.eu/
http://www.youtube.com/watch?v=eRCrUg64BLI
http://www.youtube.com/watch?v=dqGKp6C27Wc
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Heat transfer via radiation, product leaves the cooling tunnel under the dew point.
Cooling
Remoulding and package
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Cocoa liquor
Pressing
Grinding
Pulverizing
Pressed cake
Cooling
Stabilization
Packaging
Cocoa powder
Cocoa powder flow sheet
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Cocoa powder
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Flow sheet of compounds Cocoa powder, Sucrose, Cocoa butter replacers or substitudes
Forming, moulding
Milling
Mixing
Cooling
Demoulding
Package
Compound
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http://www.loynds.com
http://www.macintyre.co.uk
Compounds - Milling
Ball-mill
Impact mill
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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
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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: 385391, Aleksandra Torbica Olga Jovanovic Biljana Pajin
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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
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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
Newton liquids linear relationship between shear stress and viscosity:
Nenewton liquids linear relationship according to Casson equation :
0CA = 10 - 200 Pa CA = 1 - 20 Pas http://www.malvern.com
Chocolate Rotational Rheometer
Shear stress
dydv =
dydv.0 =
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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
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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
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4. Determination of carbohydrates by HPLC
http://www.home.agilent.com/
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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
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Sugar confectionery
11.3.2013
Amorphous sugars hard candies, jellies, caramels (toffee) Crystallised sugars - fondant, lozenges, nougat, marzipan, caramels (fudge)
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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
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Flow chart of fondant technology sucrose, water, glucose syrup
mixing
evaporation
crystalization of sucrose
wrapping
dissolving
moulding into starch
demoulding
whipping
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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
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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 %
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Hard candies Glassy state amorphous sugars
Crystals in amorphous mass
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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
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Dissolution of components and evaporation
Heat transfer - convection (jet cooker), - conduction (tube heat-exchanger and batch
cooker), - radiation.
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Solubility and boiling point of sucrose solutions
1 solubility of sucrose, 2 boiling point of sucrose solutions
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Trends of the boiling point as the mass fraction of components
100110120130140150160170180190200210220
60 65 70 75 80 85 90 95 100 105
hmotnostn zlomek x (%)
b.v.
(C
) 36 D.E.64 D.E.43 D.E.SacharosaS
Mass fraction x (%)
Sucrose
Vacuum
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http://www.bepexhosokawa.com/02confectionery/profile/profile.htm
Batch evaporator
Heat transfer -conduction
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Moulding of confectionery mass
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Forming of hard candies
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Crystallization of fondant
http://nca.files.cmsplus.com/ResidentCourse/Week2/ResCourseWk2CH3AFondant&Cream.pdf
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Moulding in starch
http://nid.com.au
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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
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Questions?
Some aspects of Chocolate and Confectionery TechnologyContentSnmek slo 3Chocolate and chocolate confectionerySnmek slo 5Snmek slo 6Snmek slo 7Composition of chocolate, viscosity and yieldLegislation of chocolate and applying of the cocoa butter equivalentSnmek slo 10Snmek slo 11Snmek slo 12Snmek slo 13Snmek slo 141, 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/ MillingRefiningConche Carle-MontanariTemper 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 butterSnmek slo 20Snmek slo 21Snmek slo 22Snmek slo 23Snmek slo 24Snmek slo 25Snmek slo 26Snmek slo 27Snmek slo 28Snmek slo 29Snmek slo 30Cocoa 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.Snmek slo 32Snmek slo 33Snmek slo 34Snmek slo 35Snmek slo 36Snmek slo 37Sugar confectioneryFlow chart of hard candies technologyFlow chart of fondant technologySnmek slo 41Hard candies and fondantSnmek slo 43Components in formulation of hard candiesDissolution of components and evaporationSolubility and boiling point of sucrose solutionsTrends of the boiling point as the mass fraction of componentsSnmek slo 48Moulding of confectionery massSnmek slo 50Snmek slo 51Moulding in starchSnmek slo 53Snmek slo 54
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