Manufacturing of chocolate Whole Process and its Defects

Manufacturing of chocolate Whole Process and its Defects

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  MANUFACTURING OF CHOCOLATE Presented By: Himanshu B.Voc FoodProcessing3rd
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  CHOCOLATE  Chocolate isa highly nutritive and widely appreciated confectionary. Because of its satisfying value and high energy.  Chocolate is made from cocoa beans and milk fat, cocoa butter.  First time chocolate was made during 2nd world war.
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  DEFINITIONS  Chocolate isa usually sweet, brown, food preparation of roasted and ground cocoa seeds that is made in the form of liquid.  Chocolate is a food made from cocoa beans. It is used in many dessert like pudding cakes, candy, ice cream.  It has a lot of antioxidant properties.  It enhance our congnitive ability and reduce cardiovascular problem.
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  DIFFERENT TYPES OF CHOCOLATE Chocolate come in many types and shapes.  Milk Chocolate :- Milk Chocolate is chocolate that contains only 10 - 40% cacao mixed with sugar and milk solid.  White Chocolate :- White Chocolate contains no cacao at all and is simply made up of cocoa butter and sugar. It has vanilla flavor.
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   Semi SweetChocolate :- Semi Sweet chocolate contains around 60% cacao and 40% sugar.  Dark Chocolate :- Dark Chocolate is chocolate that contains over 70% cacao.  Unsweetened Chocolate :- Sometimes known as baking chocolate contains 100% cacao and 0% sugar.  Chocolate Bars :- Chocolate bars nice and versatile. They melt well and if broken up into chunks.
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   Chocolate Chips:- Chocolate Chips are often treated with stabilizer to help them retain their shape.  Chocolate Wafers :- Chocolate Wafers look like large Chocolate chips and are specially formulated for easy melting.
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  INGREDIENTS USED IN CHOCOLATE Cocoa :- Cocoa is one of the raw material used in chocolate. It is found in south America in the tree of cacao.  Sugar :- Sugar is raw material found in chocolate. Sugar comes from sugar cane. Cocoa = C6H1N7O8 Sugar = C12H22011
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   Milk Component:- Skimmed milk powder or Whole Milk Powder is usually used in coating chocolate.  Lecithin :- Lecithin is an emulsifier added to reduce the viscosity and yield of coating. The addition of more than 0.5%.  Flavors :- Vanilla is the flavor used in coating formulas with levels from 0.03% to 0.05% giving cocoa flavor.
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  CHOCOLATE MANUFACTURING PROCESS  ChocolateManufacturing process generally involves mixing refining and conching of chocolate paste. Tempering and final product preparation that may include planning enrobing and molding. The final step is cooling.
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  Flow Chart Harvest &Fermentation Drying / Storage Testing & Cleaning Mixing Grinding / Refining
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  Conching Tempering Molding Chocolate
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  EXPLAINATION OF EACHSTEPS  Harvest & Fermentation :- Cacao tree produce buds an a continuous basis. The pods carefully broken.  After the cocoa pods are collected into basket  They are split open and cocoa beans are removed  Now the beans are undergoes the fermentation process  Placed in heated trays or covered with banana leaves.  This process take place 5 to 8 days.
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   Drying andStorage :- After Fermentation cocoa beans has high moisture content. They must be dried. Cocoa beans can be dried out in sun. Moisture must be reached 6 to 7%.  Mixing :- Raw material mixed with homogeneous paste with fat content with 22 to 25%. Temperature during mixing should be 55 to 60 degree Celsius.  Grinding :- Paste goes to 5 roll refiner. Transport of the product over the rolls is affected by increasing the speed.
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   Conching :-The Conching tank has a high speed impeller device. The temperature of the conching process should be 65 to 70 degree celsius. Moisture content after conching should below 1%. The time of conching is approximately 5 hours. Conching is responsible for chocolate flavor and texture.
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   Tempering :-Tempering is the cooling of the product. This is essential to ensure a good gloss snap, hardness, contraction and shelf life.  Cooling :- Chocolate need to be cooled under gentle condition at 13 to 15 degree cesius
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  Problems in Chocolate Fat Bloom :- Fat bloom is a significant problem to the confectionary industry.  It can cause uncontrolled crystallization  Poor Tempering of the chocolate  Incorrect cooling methods & including covering cold centers  Warm storage condition  Addition of Fat is incomplete.