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CHEMICAL PROCESS INDUSTRIES Date: 31/03/11 Lesson 6

COCOA PROCESSING INDUSTRY 1.0 Introduction A typical cocoa processing plant transforms cocoa beans into three main components: Cocoa liquor - Cocoa liquor is used, with other ingredients, to produce chocolate. Chocolate is used as a product on its own or combined with other ingredients to form confectionery products. Cocoa butter - Cocoa butter is used in the manufacture of chocolate. It is also widely used in cosmetic products such as moisturizing creams and soaps. Cocoa powder - Cocoa powder can be used as an ingredient in almost any foodstuff. For example, it is used in chocolate flavored drinks, chocolate flavored desserts such as ice cream and mousse, chocolate spreads and sauces, and cakes and biscuits. The processing of raw cocoa beans into cocoa mass contains a number of stages. On arrival at the processing factory the beans are subjected to thorough inspection, thereafter to be cleaned, mixed into the desired blend, fragmented and stripped of their husks. What remains is the inner part of the kernel, called nib. The nibs are heat-treated to eliminate possible bacteria ans subsequently roasted and ground into a liquid cocoa mass. The nibs are alkalized before, during or after the roasting process. This determines the colour and taste of the cocoa mass, which, as an intermediate or semi finished product, is supplied to the chocolate industry and is also basis for the production of cocoa powder and cocoa butter. 2.0 From mass to butter Fat is pressed out of the cocoa mass under high pressure. The butter is subsequently filtered, to remove the last remnants of solid cocoa ingredients. The manufacturer supplies the cocoa butter in liquid form in tankers, or in solidified form in cardboard boxes. This product is an important ingredient of chocolate. Cocoa butter can be made odorless by means of steam and vacuum extraction. The chocolate industrys demand is usually for cocoa butter with a neutral taste. Cocoa butter is also used in the production of cosmetics and toiletries. 3.0 From mass to powder

What remains after the removal of the cocoa butter through pressing are cocoa cakes. These cakes are broken up and ground into a fine cocoa powder. Each manufacturer supplies its own type of powder, with its own distinctive color, aroma, pH-value (degree of acidity) and fat content. The powder is the substance which contains the aroma, taste and color of cocoa. That is why it is the ingredient which is added to numerous food products for flavor and color: biscuits, puddings, deserts, creams, filled chocolates, ice cream etc. Mixed with sugar and diluted with milk it turns into a mild chocolate drink. It also provides the finishing touch for confectionary, truffles and cappuccino coffee, while new applications are being made all the time. 4.0 The manufacturing of chocolate 4.1 Cleaning and Roasting Cocoa beans are carefully cleaned and sorted at the factory, and then roasted. Waste moisture and acid compounds evaporate during the roasting process, and the beans become a uniform shade of deep-brown. Cocoa roasting is a very important stage of the whole manufacturing process, and the future quality of the chocolate, and its smell and taste depend on it just as much as they do on fermentation. Sometimes different grades of cocoa (or cocoa of one grade, but grown in different countries) are mixed for roasting. The majority of the major chocolate manufacturers keep their methods and conditions of roasting a secret. After roasting, the shells are removed and the cocoa beans are crushed into cocoa nibs. 4.2 Cocoa liquor Roasted and cleaned cocoa-nibs are carefully ground into cocoa liquor. The finer the cocoa-nibs are ground at this stage, the fuller and finer the taste of the chocolate. 4.3 Pressing The cocoa liquor contains 54% cocoa butter, the very valuable substance essential for the production of real chocolate. Cocoa liquor is heated up to 95105 C and is then pressed. As a result, cocoa butter is separated from the solids, which are subsequently used for the production of cocoa powder. 4.4 Mixing and grinding Cocoa liquor, sugar and part of the cocoa butter are mixed in specified proportions. After mixing the mass is ground. This stage is very important for the

production of chocolate: the finer the crushing, the more delicate the taste. Please note that the overall content of natural cocoa-products in such a mix largely determines not only the quality, but also the cost of the chocolate. This especially concerns the contents of cocoa-butter, an extremely valuable and expensive product.

4.5 Conching After mixing and grinding the chocolate mass is subjected to conching: intensive mixing at high temperature. Conching is a very long (up to 24 hours) process and, as a result, the excess moisture and the residual tannins are evaporated from the chocolate mass, and the cocoa solids are rounded off. The consistency of the chocolate becomes more homogeneous, and the tastegentler, the well-known melt in the mouth effect. After processing the chocolate mass, the rest of the components are added according to the recipe: cocoa butter and lecithinfor mass attenuation and optimized moulding; natural flavoring agent (vanilla)for a subtler and more delicate aroma. 4.6 Tempering Tempering is a key part of chocolate production. It is a long and complex process, which requires great experience and skill. After conching, the hot chocolate mass should be cooled, but it requires several stages to do this, because of the cocoabutter contents. The problem is that cocoa-butter is a polymorphic fat, which crystallizes and congeals while cooling, but can take on different consistencies according to cooling conditions. Tempering is necessary for the cocoa butter to obtain the most stable consistency. For this purpose, the hot chocolate is at first cooled down to 28 , and then reheated to 32 . If the process is upset at any one of the tempering stages, this will be reflected in the appearance and consistency of the chocolate. For example, a characteristic white bloom can appear on its surface. Such a bloom is the result of incorrect tempering. Moreover, the bloom does not appear at once, but some time later. Also, the chocolate can become hard-grained and crumbly due to incorrect cooling. In this case, its taste properties will be retained, but its appearance for marketing purposes will be hopelessly damaged. 4.7 Moulding After tempering, the chocolate is poured into heated moulds. At this stage, if the recipe requires it, various additives (for example, nuts) are put into the chocolate. After that, the chocolate is put into coolers. The chocolate solidifies and

a beautiful shine appears on its surface. Then the moulds with the solid chocolate are upturned and shaken on to the conveyor. 4.8 Packaging and labelling The last stage in the manufacture of chocolate is its packaging and labeling.

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