FLOW PROCESS OF COCOA PROCESSING PLANT

The plant is fully equipped with :

1. Cocoa Bean Cleaning System

Once in the processing plant, the beans are separated from foreign matter with a machinery that
consists of mesh, magnetic separators and aspiration channels.Cocoa Bean Cleaning consist of : a.
Sieving Machine

b. Metal / Magnet Separator

c. Stone Separator / Destoner

d. Dumping Station

e. Bucket Elevator
f. Screw Conveyor

g. Aspiration pipe to Cyclone + Rotary Valve and Centrifugal Blower h. Platform

2. Pre-Drying System

The beans rotate around a ceramic drum heated with infra-red which separates the shell from the nib.
This achieves the “popping effect” and extraneous matter that could contaminate the product during
later stages of the process is burned off.

Pre-Drying consist of :

a. Bucket Elevator

b. Screw Conveyor

c. Infrared Dryer

d. Dumping Station

e. Aspiration pipe to Cyclone + Rotary Valve and Centrifugal Blower

f. Platform

3. Winnowing / Dehulling System

The bean is broken into pieces and the shell is removed with the aid of different meshes and vacuum
suction. The de-shelled broken bean is called the “nib”.

Winnowing consist of :

a. Bucket Elevator

b. Impact Crusher

c. Winnower Machine

d. Dumping Station

e. Aspiration pipe to Cyclone + Rotary Valve and Centrifugal Blower f. Platform

4. Alkalizing and Roasting System

By adding Potash solution (K2CO3) or an equivalent, the pH of the product is increased and the color is
changed. This process is used to obtain a wide range of colors in the final product – cocoa powder.

The nibs are roasted and sterilized. It is in this stage that color and flavor are developed. Times and
temperatures are critical at this stage and are crucial in rendering the optimal product.Alkalizing and

Roasting consist of :

a. Alkalizer
b. Bucket Elevator

c. Screw Conveyor

d. Roaster Machine

e. Cooler Machine

f. Dumping Station

g. Aspiration pipe to Cyclone + Rotary Valve and Centrifugal Blower h. Platform

5. Grinding / Refining System

The particle is reduced with three different stages of milling. The paste obtained is called cocoa liquor.

Grinding / Refining consist of :

a. Bucket Elevator

b. Screw Conveyor

c. Pre-Grinding (1st stage of grinding)

d. Intermediatte Grinding / Ball Mill (2nd stage of grinding)

e. Fine Grinding / Ball Mill (3rd stage of grinding)

f. Sieving Machine

g. Collecting Vessel

h. Transporting system / Fluid pump + piping system

6. Cocoa Butter Pressing System

Before pressing, the cocoa liquor is conditioned by mixing and heating. It is then pressed and the cocoa
butter is extracted. The remaining solids inside the filter become compressed and, at the end of the
cycle, they fall into a conveyor. The resulting product is called cocoa cake.Cocoa

Butter Pressing consist of :

a. Cocoa Liquor Handling

b. Press Tank

c. Transporting system / Fluid pump + piping system

d. Cocoa Butter Pressing Machine

e. Cake Conveyor

f. Cake Breaker
g. Screw Conveyor

h. Filter Press

7. Cocoa Butter or Liquor Blocking System

The butter is filtered and deodorized to eliminate any remaining cocoa solids. It is then cooled and
packed, but for the cocoa liquor it is just cooled and packed.

Cocoa Butter Blocking consist of :

a. Cocoa Butter Handling

b. Storage Tank

c. Transporting system / Fluid pump + piping system

d. Tempering Machine

e. Weighing System + Packing

f. Heating and Cooling System

g. Cooling Tunnel
8. Cocoa Powder Plant System

The cocoa cake in the conveyor is pushed to a breaker and reduced to a powder with the use of a pin
mill. It then passes through a crystallizer in order to obtain a powder with stable crystals which render a
stable color in the powder and prevent agglomeration of the particles.

Cocoa Powder Plant consist of :

a. Cocoa Cake Handling

b. Screw Cooling

c. Bucket Elevator

d. Cake Grinding Machine

e. Dumping Station

f. Crystallizer

g. Aspiration pipe to Cyclone + Rotary Valve and Centrifugal Blower h. Weighing System +

COCOA PROCESSING MACHINE

WINNOWERS
BALL MILL / REFINER
NIBS GRINDER
Cocoa Liquor Flow
1. Cocoa Liquor
2. Cocoa Butter (After Pressing)
3. Cocoa Cake (After Pressing)
COCOA PROCESSING

Definitions
The U.S. Food and Drug Administration (FDA) has established Standards of Identity for various
cacao products (21 Code of Federal Regulations Part 163). These standards designate the names
of the cacao products as well as the percentage of key ingredients that must be present.

Cacao – used in the FDA regulations to refer to the bean which is the source of the cacao
components chocolate liquor, cocoa butter, and cocoa powder.

Chocolate liquor - produced by grinding the cacao bean nib (or center) to a smooth, liquid state.
In the U.S., chocolate liquor can also be called chocolate, unsweetened chocolate, baking
chocolate, or bitter chocolate. In Canada and Europe, other names include cocoa (cacao) mass
and cocoa liquor.

Cocoa butter - the fat naturally present in cacao beans. The amount of cocoa butter in cacao
beans typically ranges from 50 to 60%, with the balance being non-fat cocoa solids.

Cocoa or cocoa powder - the product made by removing part of the fat (i.e.,cocoa butter) from
the cocoa bean and grinding the remaining material to a powder.

SMALL COCOA PROCESSING PLANT

The above chart is showing how to process cocoa beans into
Cocoa Liquor / cocoa mass
The plant is equipped with :
1. Pre-Drying machine
2. Winnowing / Deshelling machine
3. Roasting & Cooling machine
4. Grinding machine
5. Transporting such as :
a. Screw Conveyor
b. Bucket Elevator
c. Fliud Pump / Gear pump + Piping
d. Dumping Station
e. Aspiration pipe to Cyclone and Centrifugal Blower
f. Platform

CHOCOLATE GLOSSARY

Antioxidants:

Compounds that protect cells against the damaging effects of reactive oxygen species by “quenching”
the oxygen appetite of free radicals – unstable oxygen molecules that cause damage to cells, DNA and
tissues. Research suggests that consumption of antioxidant-rich foods, including cocoa and dark
chocolate, reduces damage to cells from free radicals. This may slow down, prevent, and even reverse
certain diseases that result from cellular damage, and perhaps even slow down the natural aging
process
Blending:

The process which occurs after roasting and before grinding. Crushed beans are blended, determining
the flavor of the chocolate.

Bittersweet (or Semisweet) Chocolate:

The darkest of eating chocolate with the highest percentage of chocolate liquor that contains extra
cocoa butter to make it melt easily. Years ago, “bittersweet” referred to European dark chocolate, with
“semisweet” attached to American dark chocolate. According to US regulations called the Standards of
Identity (SOI), both bittersweet and semisweet must contain at least 35% chocolate liquor. Generally,
semisweet chocolate contains 35-45% chocolate liquor. Bittersweet chocolate typically contains at least
50% chocolate liquor, resulting in a stronger chocolate flavor.

Cacao, chocolate or cocoa nibs:

Coarse piece that are the center (meat) of the cocoa bean, the basis of all cocoa –based products,
including chocolate. Following removal of the outer cocoa bean shell, nibs are roasted and crushed
between a series of heavy steel rollers or grinding stones; the frictional heat forms what is known as
chocolate liquor (See chocolate liquor). Nibs contain about 53 percent cocoa butter (See cocoa butter).

Catechin:

A powerful, water soluble polyphenol and antioxidant that is easily oxidized. It is believed to have some
value in fighting tumors as well as enhancing immune system function. Cocoa nibs are an excellent
source of catechins.

Chocolate Liquor:

The ground up center (nib) of the cocoa bean (otherwise known as unsweetened baking chocolate) in a
smooth, liquid state. It contains no alcohol. Also called "chocolate liquid."

Cocoa Beans:

Seeds from the pod of Theobroma cacao, a tree native to the tropical Amazon forests. Commercially
grown worldwide in tropical rainforests within 20° latitude of the equator.

Cocoa Butter:

The natural fat from the cocoa bean, obtained by pressing chocolate liquor. It is not a dairy product.

Cocoa Powder:

The cocoa solids resulting from pressing cocoa butter out of chocolate liquor. May be natural or
dutched.

Compound:
Known as confectionery coating. A blend of sugar, vegetable oil, cocoa powder and other products.
Vegetable oil is substituted for cocoa butter to reduce the product cost and to make the coating easier
to work with.

Dark Chocolate:

Also known as “sweet chocolate.” A general term for chocolates containing 15 – 35% chocolate liquor
and less than 12% milk solids, as well as sweeteners and cocoa butter.

Dutch (or Dutched) Process:

A treatment used during the making of cocoa powder in which cocoa solids are treated with an alkaline
solution to neutralize acidity. This process darkens the color of the cocoa and develops a milder
chocolate flavor.

Enrobing:

The act of coating a candy center by pouring chocolate over it, usually by mechanical means.

Epicatechin:

A smaller, simple flavanol that is found in red wine, tea and in abundant quantities in cocoa beans. May
have potential heart health benefits, and has been found to have insulin-like effects.
Fat Bloom:The result of inadequate tempering or temperature abuse of a properly tempered chocolate.
Visible as a dull white film on the surface of the chocolate with the possibility of a soft or crumbling
texture on the interior. While visually undesirable, the product is fine and safe to eat.

Fermentation:

A natural process by which bacteria, yeast and molds modify the composition of cocoa bean, so that
when the beans are roasted, they yield characteristic chocolate flavor.

Flavanols:

Flavanols are a distinct group of compounds within the flavonoids family – plant compounds that can be
found in a variety of foods and beverages, such as cocoa, red wine, green tea and certain fruits and
vegetables. The predominant flavonoids in cocoa are flavanols.

Flavonoids:

A class of plant secondary metabolites based around a phenylbenzopyrone structure. Flavonoids are
most commonly known for their antioxidant properties, protecting against oxidative and free radical
damage. Flavonoids are part of a broader class of compounds known as polyphenols.

Free Radicals:

Unstable oxygen molecules that cause damage to cells, DNA and other biological entities. Imbalance
between antioxidants and free radicals causes "oxidative stress." Free radicals have been linked to
cancer, aging, atherosclerosis, neurodegenerative diseases (Parkinson's & Alzheimer's).

Grinding:

Mechanical process of pulverizing the roasted cocoa bean nib to a smooth liquid known as chocolate
liquor.

Lecithin:

A natural food additive which acts as an emulsifier and surface active agent. Virtually all commercial
lecithin products are derived from soybean. In chocolate manufacture lecithin controls flow properties
by reducing viscosity. Typical usage levels range from 0.1 - 0.5%.

Milk Chocolate:

The best known kind of eating chocolate, it is made by combining chocolate liquid, cocoa butter, milk or
cream, sweetening, and flavorings. All milk chocolate made in the US contains at least 10% chocolate
liquor and at least 12% milk solids.

Natural Process:

Non-alkalized chocolate liquor or cocoa processed without an alkaline treatment.

Nib:

The center (meat) of the cocoa bean. Roasted or unroasted cocoa beans are mechanically cracked,
allowing the separation of the cocoa bean shell from the cocoa nib.

Oxygen Radical Absorbance Capacity (ORAC):

The measure of a food’s antioxidant power.

Polyphenol:

A broad class of naturally occurring compounds found in plants, characterized by the presence of more
than one phenol group per molecule. Over 8,000 polyphenols have been identified in plants.

Press Cake:

Product remaining after most of the cocoa butter has been pressed from the chocolate liquor. Press
cake is pulverized to make cocoa powder

Procyanidin:

A subclass of flavonoids.

Roasting:
Cooking or heating process using high temperature or dry heat which fully develops the chocolate flavor
of the cocoa beans.

Semisweet Chocolate:

Like bittersweet chocolate, semisweet chocolate is required by the US Standards of Identity to contain at
least 35% chocolate liquor. Generally, semisweet chocolate contains 35 - 45% chocolate liquor.

Single origin cocoa or chocolate:

Made using cocoa beans from a select region and/or country for a distinct flavor profile.

Sugar Bloom:

Visible as a dull white film on the surface of the chocolate, usually dry and hard to the touch, the result
of surface moisture dissolving sugar in the chocolate and subsequent re-crystallization of the sugar on
the chocolate surface. Typically caused by cold chocolate being exposed to a warm humid environment
with resultant condensation forming on the product. A visual and textural defect only; the product is
fine to eat.

Tempering:

A process of preparing chocolate that involves cooling and heating so that it will solidify with a stable
cocoa butter crystal form. This process is used to prepare chocolate for coating and dipping. Proper
tempering, followed by good cooling, is required for good surface gloss and to prevent "fat" bloom.

Unsweetened Chocolate:

Same as "chocolate liquor." The chocolate liquor is cooled and molded into blocks that can be used for
baking.

White Chocolate:

A blend of cocoa butter, milk, sugar, and flavor. Not really “chocolate” since no chocolate solids other
than cocoa butter are present, which explains the lack of brown color. In the US, since 2004, white
chocolate needs to be at least 20% (by weight) cocoa butter, at least 14% total milk solids, and less than
55% sweeteners (such as sugar).

Winnowing:

Process of cracking and removing the cocoa bean shell, which reveals the inner part of the bean (the
nib).

HOW CHOCOLATE IS MADE

CHANGES IN PHENOLIC PROFILES AND ANTIOXIDANT ACTIVITIES
FROM COCOA TO CHOCOLATE DURING THE CHOCOLATE
PROCESSING
PALM BASED CHOCOLATE PRODUCTS

CHOCOLATE gives people great pleasure when eaten. It also makes a suitable gift for many
occasions. The fat content of chocolate varies from 28% to 35% depending on its intended use.
Cocoa butter obtained from cocoa beans or specialty fats obtained from vegetable oils and fats
are the usual sources of fats for chocolate manufacture.

Specialty fats include cocoa butter equivalent (CBE), cocoa butter substitute (CBS), general
purpose coating fats and toffee fat. Palm oil and palm kernel oil are ideal raw materials for the
production of specialty fats due to their excellent physico-chemical properties. They can be
further modified to extend their range of utilisation. CBE are specialty fats which contain
symmetrical unsaturated triacylglycerols similar to that of cocoa butter (Table 1).
CBE are often regarded as fully compatible to cocoa butter. Generally, CBE is formulated with
palm mid fraction (PMF) blended with illipe and shea fats. CBS are classified as lauric- and
nonlauric- based. Lauric CBS are derived from the two major lauric oils namely palm kernel oil
and coconut oil. Palm kernel oil can be fractionated to give palm kernel stearin with similar
physical properties to that of cocoa butter. The stearin, with or without hydrogenation, is an
excellent.

CBS suitable for the manufacture of solid or hollow-moulded chocolate products. Non-lauric
CBS are made from oils such as palm, soybean, cottonseed and peanut oils. They have to be
hydrogenated in order to bring their consistency to appropriate levels. These products have
excellent uses in compound coating for biscuits, enrobed products and chocolateflavoured baking
chips. In products where price consideration is important, this type of CBS is a good alternative.

Advantages of Using Palmbased Fats in Chocolate Products

Do not require tempering

Chocolate based on CBS crystallises rapidly into stable there is no need for tempering. This
saves processing time.β’ crystal form, thus form stable crystals and are less subject to bloom
Chocolate made with CBS has a good resistance to fat bloom, thus the productlooks shiny and
attractive.
Have rheological properties suitable for modern and highly flexible production lines
The same production plant for pure cocoa butter chocolate can be used.
Stable in hot climates
The melting properties of the fat are higher than those of cocoa butter due to the stearic-oleic-
stearic (StOSt) triglyceride content. It is more stable in hot climates than cocoa butter.
Consistent quality
CBS has a low iodine value (IV), indicating low levels of unsaturated fatty acids. Thus, palm-
based CBS are stable against oxidative deterioration.
Reliable supply
Palm oil and palm kernel oil can be
obtained at all times of the year. The oils especially from Malaysia, which are of high quality, are
readily available to be processed for CBE and CBS production.
The fats are bland in flavour. They can be used for chocolate-flavoured end products, white
compounds and pastels. The fats are also compatible to a certain degree with milk fat and other
non-lauric oils.

Manufacturing Process

Economical

The price of these fats is highly competitive than that of cocoa butter.
Costs can be reduced by replacing part of the cocoa butter with CBE or by replacing the total
amount of cocoa butter with CBS.
Plain chocolate contains sugar, cocoa mass, 10% cocoa butter and 5% CBE. Milk chocolate
contains sugar, full cream milk powder, cocoa mass, 15% cocoa butter and 5% CBE. In
chocolate pastel, the cocoa is omitted. The colour of chocolate pastel is basically white and
colour can be added to make it more attractive.

Processing

The ingredients are pre-mixed. Melted fat is added and mixed until smooth. It is then refined,
conched, tempered, moulded, cooled and demoulded. The chocolates are then stabilised to
complete crystallisation.

1. Pre-mixing
aw materials, i.e. cocoa liquor, sugar and milk powder, are mixed with an adjusted fat content
(26 ±1%) before the mass is refined.

2. Refining
It is important to refine chocolate paste in order to obtain the required smoothness. The mass is
ground until 80% of particle size distribution is between 20-30μ . A roll refiner is commonly
used for this purpose.

3. Conching
This process is characterised by chemical and physical change in the product mix. Flavour
develops during the process and water content is reduced to less than 1%. A homogenous
product mass is produced in an efficient homogeniser and this is a crucial step. During conching,
good temperature control is essential. Temperature for plain chocolate is 65 oC- 90oC and for
milk chocolate 50oC-65oC. Time for conching depends on the composition of the mass but it is
normally more than three hours and often longer for plain chocolate.

4. Tempering
Tempering of the chocolate mass based on CBS is carried out by heating the mass at 50 oC the
quoted slip melting point of the fat. For CBE-based chocolate, it is necessary to form the right
amount of stable crystal in the chocolate mass to enable moulding.
The mass is heated at 50 to 26.5 - 25.5 oC-60oC and cooling it to at least 2oC aboveoC-60oC
and cooledoC-27.5oC for plain chocolate andoC-26.5oC for milk chocolate.
5. Moulding
Temperature of the mass is raised to 31 oC. The chocolate is then cooled in a cooling cabinet set
at 5 oC-33oC (plain chocolate) and 29oC- 31oC (milk chocolate) respectively before moulding.
Temperature of the mouldshould be 2oC-5oC lower than the moulding temperature of the mass.
The chocolate mass is filled into the mould, tapped and strapped of excess chocolate.oC-12oC.

6. Cooling and Demoulding

A suitable cooling cabinet with air circulation and sufficient cooling capacity should be used.
Cooling temperature is usually between 5 45 minutes (normally 15-20 minutes). For easy
demoulding, the shrinkage should besufficient. Difficult demoulding may be caused by
- mould not being sufficiently cleaned
- chocolate not being properly tempered
- temperature of the mould not being appropriate oC-12oC and time should not exceed

The finished products are stabilised at 18 crystallisation. Plain and Milk Chocolate Formulation
Using CBE oC-20oC for at least 24 hours to complete
Posted by Serpil Acar at 8:42 PM 0 comments

THE PROCESS OF CHOCOLATE MANUFACTURING

The cocoa-bean -- the heart of the sweetest delicacy in the world -- is bitter! This is why, up to
the 18th century some native tribes ate only the sweetish flesh of the cocoa fruit. They regarded
the precious bean as waste or used it, as was the case among the Aztecs, as a form of currency.
The VarietiesThere are two quite different basic classifications of cocoa, under which practically
all varieties can be categorised: Criollo and Forastero cocoas. The pure variety of the Criollo
tree is found mainly in its native Equador and Venezuela. The seeds are of finer quality than
those of the Forastero variety.

They have a particularly fine, mild aroma and are, therefore, used only in the production of high-
quality chocolate and for blending. However, Criollo cocoa accounts for only 10% of the world
crop. The remaining 90% is harvested from trees of the Forastero family, with its many hybrids
and varieties. The main growing area is West Africa. The cocoa tree can flourish only in the
hottest regions of the world.

The Harvest immediately after harvesting, the fruit is treated to prevent it from rotting. At
fermentation sites either in the plantation or at, collecting points, the fruit is opened.
FermentationThe fermentation process is decisive in the production of high quality raw cocoa.
The technique varies depending on the growing region.

Drying
After fermentation, the raw cocoa still contains far too much water; in fact about 60%. Most of
this has to be removed.

What could be more natural than to spread the beans out to dry on the sun-soaked ground or on
mats? After a week or so, all but a small percentage of the water has evaporated.

Cleaning

Before the real processing begins, the raw cocoa is thoroughly cleaned by passing through
sieves, and by brushing. Finally, the last vestiges of wood, jute fibres, sand and even the finest
dust are extracted by powerful vacuum equipment.

Roasting

The subsequent roasting process is primarily designed to develop the aroma. The entire roasting
process, during which the air in the nearly 10 feet high furnaces reaches a temperature of 130 °C,
is carried out automatically.

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.

Crushing and shelling

The roasted beans are now broken into medium sized pieces in the crushing machine.

Blending

Before grinding, the crushed beans are weighed and blended according to special recipes. The
secret of every chocolate factory lies in the special mixing ratios which it has developed for
different types of cocoa.

Grinding

The crushed cocoa beans, which are still fairly coarse are now pre-ground by special milling
equipment and then fed on to rollers where they are ground into a fine paste. The heat generated
by the resulting pressure and friction causes the cocoa butter (approximately 50% of the bean)
contained in the beans to melt, producing a thick, liquid mixture.

This is dark brown in colour with a characteristic, strong odour. During cooling it gradually sets:
this is the cocoa paste.

At this point the production process divides into two paths, but which soon join again. A part of
the cocoa paste is taken to large presses, which extract the cocoa butter. The other part passes
through various blending and refining processes, during which some of the cocoa butter is added
to it. The two paths have rejoined.

Cocoa Butter

The cocoa butter has important functions. It not only forms part of every recipe, but it also later
gives the chocolate its fine structure, beautiful lustre and delicate, attractive glaze.

Cocoa Liquor

Roasted and cleaned cocoa-nibs are carefully ground. The finer the cocoa-nibs are ground at this
stage, the fuller and finer the taste of the chocolate. The size of the cocoa particles passed
through the grinding machinery, should not exceed 75 microns—such cocoa is called coca
liquor.

These cakes are crushed again, ground to powder and finely sifted in several stages and we
obtain a dark, strongly aromatic powder which is excellent for the preparation of delicious drinks
- cocoa. Cocoa paste, cocoa butter, sugar and milk are the four basic ingredients for making
chocolate. By blending them in accordance with specific recipes the three types of chocolate are
obtained which form the basis of ever product assortment, namely: ( A or B Process)

A-Kneading

In the case of milk chocolate for example, the cocoa paste, cocoa butter, powdered or condensed
milk, sugar and flavouring - maybe vanilla - go into the mixer, where they are pulverized and
kneaded.

Rolling

Depending on the design of the rolling mills, three or five vertically mounted steel rollers rotate
in opposite directions. Under heavy pressure they pulverise the tiny particles of cocoa and sugar
down to a size of approx. 30 microns. (One micron is a thousandth part of a millimetre.)

B-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 95−105 °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.

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. But in various cheap substitutes cocoa-butter is almost invariably absent. It is the reason
for the so-called “attractive” prices, which are used by not too scrupulous manufacturers to
please not very experienced clients.

Conching
But still the chocolate paste is not smooth enough to satisfy our palates. But within two or three
days all that will have been put right. For during this period the chocolate paste will be refined to
such an extent in the conches that it will flatter even the most discriminating palate.
Conches (from the Spanish word "concha", meaning a shell) is the name given to the troughs in
which 100 to 1000 kilograms of chocolate paste at a time can be heated up to 80 °C and, while
being constantly stirred, is given a velvet smoothness by the addition of certain amounts of cocoa
butter. A kind of aeration of the liquid chocolate paste then takes place in the conches: its bitter
taste gradually disappears and the flavour is fully developed. The chocolate no longer seems
sandy, but dissolves meltingly on the tongue. It has attained the outstanding purity which gives it
its reputationCocoa PowderAfter the cocoa butter has left the press, cocoa cakes are left which
still contain a 10 to 20% proportion of fat depending on the intensity of compression.

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 superfluous
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 taste—
gentler, 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 lecithin—for mass
attenuation and optimized moulding; natural flavoring agent (vanilla)—for a subtler and more
delicate aroma.

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 cocoa-butter 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 °С, and then reheated to 32 °С. 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.

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.
Packaging and labelling

The last stage in the manufacture of chocolate is its packaging and labeling. And if the chocolate
is made by the VK company, it will have the precise packaging you, the customer, have ordered.

Conditions and length of storage

Chocolate should be transported and stored at 18±3 °С, with a relative humidity of less than
75%. If these conditions are not observed, the chocolate can bloom and lose its marketable
appearance.
Posted by Serpil Acar at 7:35 PM 0 comments

SUGAR AND FAT BLOOM

It is not uncommon for a chocolate bar or box of chocolate confections to be opened and the
chocolate is no longer shiny. Instead, it looks as if the chocolate has spoiled and is covered with
white or light brown colored splotches. While it may look as if the chocolate has spoiled, the
chocolate is in fact edible.

What has occurred is that the chocolate has undergone a process called "bloom." There are two
main types of chocolate bloom. The first is sugar bloom and the second fat bloom. Each has
different causes. However, no matter the type of bloom, the surface of the chocolate will become
unappealing and will have a mottled or hazy look. If fat bloom is present, it is likely that the
texture of the chocolate may have changed from when it was originally molded.

Sugar Bloom

Sugar bloom is caused by moisture coming into contact with the chocolate. Chocolate is
composed of ground cocoa beans and sugar, and sometimes vanilla and lecithin. While you may
not see the sugar crystals present in chocolate, they are there. They simply are too small to see.
Water when it comes in contact with the chocolate, dissolves the sugar on the surface of the
chocolate. As the water dries, the dissolved sugar crystallizes and precipitates onto the surface of
the chocolate. The resulting small sugar crystals give the chocolate a dusty appearance.
The sugar bloom may have occurred in a number of ways. The most obvious of is that water was
inadvertently spilled on the chocolate, or the chocolate came in contact with or was placed on
something wet. Sugar bloom may occur in other not so obvious ways. For example, if the
chocolate was placed in the refrigerator where it became cold and then removed and placed in
open air, the cold chocolate will condense moisture from the air, and the condensation will cause
the sugar bloom. Sugar bloom may also occur if the chocolate has been in an environment with
too high a humidity.

The best way to avoid sugar bloom is to store your chocolate in an area of low humidity and
stable temperature so as to avoid condensation. If the chocolate is cold, such as when it has been
stored in the refrigerator, it should be covered (perhaps with a towel) so that it will warm slowly
and air circulation is minimized.

A Simple Test

One way you can easily check to see if a piece of chocolate has undergone sugar bloom or fat
bloom is to lick your finger and touch it to the chocolate. If the dusty appearance disappears,
then it is sugar bloom. (The moisture on your finger dissolved the sugar crystals on the
chocolate.) If the bloom remains, then it is fat bloom.

Fat Bloom

Fat bloom, unlike sugar bloom, is not always caused by a simple set of circumstances, such as
the chocolate becoming wet. Fat bloom is more complicated, and oftentimes it may be more
difficult to discover the actual source of the problem.
Fat bloom typically appears as lighter color spots on the chocolate. As the name implies, the
bloom is composed of fat, in this case the naturally occurring fat that comes from the cacao bean
-- cocoa butter.

When discussing the reasons for fat bloom, it is important to note that when
cocoa butter hardens, it forms crystals. Some of the crystals are stable, but other crystals are not
and will actually change form over time. During chocolate manufacturing, a process called
tempering is used to ensure that only stable crystals form, while the chocolate hardens. Fat
bloom is caused by the interaction of the various types of crystals or the tempering process (or
lack thereof).

An example of severe fat bloom in completely untempered chocolate

If chocolate is not tempered, the unstable forms of cocoa butter crystal will form, most notability
the Beta Prime and Alpha forms. After the cocoa butter hardens, these unstable forms will slowly
change their forms to the stable Beta form. The Beta crystals are slightly smaller than the Beta
Prime or Alpha forms, so that when this transition occurs, the chocolate contracts. The new
stable Beta crystals then form, projecting above the surface of the chocolate, visible as bloom. If
the chocolate is stored in a room where the temperature fluctuates near the melting temperature
of the stable Beta crystals, two additional types of fat bloom may form. In the first, some of the
Beta crystals melt. When they recrystalize, they recrystalize slowly, since the ambient
temperature is close to that of the chocolate. This allows the crystals to grow much larger than
the original small, compact crystals. In addition to projecting above the surface of the chocolate,
these larger crystals may displace cocoa butter, forcing it to the surface. The second type of
bloom is created when the crystals have softened instead of melted. It is during this period that
cocoa butter that has slightly melted migrates toward the surface. When it breaks the surface, it
pools ever so slightly, and when it cools the cocoa butter appears as spots.

An example of fat bloom on a chocolate bar

Many people are surprised to learn that fat bloom also occurs in cocoa powder. Cocoa powder
contains between 12-20% cocoa butter. Since some cocoa butter is present, it must be tempered
during manufacturing, just as chocolate is. Cocoa powder that has been improperly tempered or
undergone temperature fluctuations may cause bleaching of the cocoa powder and may cause
clumping as the cocoa butter helps the particles of the cocoa powder adhere to each other. As
with chocolate, when bloom occurs it does not affect the edibility of the cocoa powder but may
have an aesthetic impact.

Studies on fat bloom indicate that the bloom consists of large, single cocoa butter crystals or
collections of crystals of the stable Beta form of cocoa butter. Other forms of cocoa butter
crystals are not present in fat bloom.
Fat blooming actually occurs in a third process. This case affects not so much the chocolate
industry directly but the ancillary confectionary industry. When chocolate is used to coat nuts or
fillings that contain oils or fats (such as nut butters) that are incompatible with chocolate, the oils
may actually seep into or through the chocolate over time. This is called fat migration. As the
oils displace the cocoa butter, cocoa butter may seep onto the surface of the piece of
confectionary and recrystalize as bloom. When this occurs, the manufacturing process needs to
be examined or the confectionary reformulated.

If fat bloom is present and the chocolate is not newly cast, then temperature fluctuations should
be the first thing looked at. If an air conditioner is in use, the outlet may be too close to the
chocolate (causing temperature fluctuations as the air conditioner turns on and off), or it may
simply be undersized for the room to be cooled. If the chocolate was recently molded, the temper
of the chocolate is suspect, and adjustments to the temper procedure may be required.

Fat Bloom as Quality Indicator

Fat Bloom is a good indicator that the chocolate may not be in good condition. It is not
uncommon for chocolate that has bloomed to undergo other changes. For example, it may have
lost its temper. When chocolate has properly crystallized, it will have a shiny finish, have a nice
snap when broken, and will melt at approximately 95 degrees Fahrenheit (35 C). If chocolate is
stored in a room where the temperature has fluctuated or has become too hot, the chocolate will
recrystallize. When this happens, the cocoa butter crystals will regrow in an uncontrolled fashion
and will likely result in fat bloom. While fat bloom may be only an aesthetic problem, chocolate
where fat bloom is present should be examined to ensure that its temper remains intact. If the
chocolate will be melted and then remolded or used in baking, neither sugar nor fat bloom will
appreciably affect the quality of the final product. The one exception to this is where fat
migration has occurred, such as may happen in the confectionary industry.

In an effort to eliminate bloom, some manufacturers will add a variety of fats and their
derivatives (most notably stearins) to the chocolate prior to molding. This provides only a limited
amount of protection from bloom, though as of yet, there is no bloom-free chocolate. Of course,
at Amano Chocolate, we do not use additives to prevent bloom, nor do we encourage their use.
Instead, at Amano we choose to watch our manufacturing practices with added diligence.
Chocolate simply means too much to us to adulterate it.
Posted by Serpil Acar at 7:15 PM 0 comments
Labels: Fat Bloom, SUGAR BLOOM

EFFECTS OF TEMPERING AND FAT CRYSTALLISATION BEHAVIOUR

ON MICROSTRUCTURE MECHANICAL PROPERTIES AND
APPEARANCE IN DARK CHOCOLATE SYSTEMS

Fat crystallisation behaviours in dark chocolates from varying particle size distribution (PSD)
(25, 35 and 50 over-temper and under-temper), and their effects on mechanical properties and
appearance evaluated.Microstructures of derived products were determined using stereoscopic
binocular microscopy. Wide variations in mechanical properties and appearance were noted in
products from different particle size and temper regimes. Particle size (PS) was inversely related
with texture and colour, with the greatest effects noted in hardness, stickiness and lightness at all
temper regimes. Over-tempering caused significant increases in product hardness, stickiness with
reduced gloss and darkening of product surfaces.Under-tempering induced fat bloom in products
with consequential quality defects on texture, colour and surface gloss. Micrographs revealed
variations in surface and internal crystal network structure and inter-particle interactions among
tempered, over-tempered and under-tempered (bloomed) samples.Under-tempering caused
whitening of both surface and internal periphery of products with effects on texture and
appearance. Thus, attainment of optimal temper regime during pre-crystallisation of dark
chocolate was central to the desired texture and appearance as both over-tempering and under-
tempering resulted in quality defects affecting mechanical properties and appearance of products.

1. Introduction

Tempering is a technique of controlled pre-crystallisation employed to induce the most stable

solid form of cocoa butter, a polymorphic fat in finished chocolates. The process consists of
shearing chocolate mass at controlled temperatures to promote crystallization of triacylglycerols
(TAGs) in cocoa butter to effect good setting characteristics, foam stability, demoulding
properties, product snap, contraction, gloss and shelf-life characteristics. Time–temperature
protocols and shearing are employed to induce nucleation of stable polymorphs with the
formation of three-dimensional crystal network structure influencing the microstructure,
mechanical properties and appearance of products. The crystal network organisation and the
polymorphic state of the TAGs crystals as affected by the crystallisation conditions are major
factors determining rheological and textural properties of crystallised TAGS systems (Herrera
and Hartel, 2000; Narine and Marangoni, 1999;).Lipp and Anklam, 1998; Segall). These occur as
symmetric triacyglycerolsChevalley,; Beckett, 2000; Afoakwa et al., 2007b; Do et al., 2007;
Afoakwa). Smaller particles improve sensory propertiesZiegler et al., 2001) but plastic viscosity
and yield stress increasedistribution and ultimately sensory character in consumption and product
identification.

Instrumental measurements can act as complements for sensory evaluations (Lawless and
Heymann, 1998) with statistically significant correlations (Mohamed et al., 1982; Meullenet et
al., 1997; Rosenthal, 1999; Ali et al., 2001; Bourne, 2002). Appropriate strategies can objectively
assess features of texture and appearance such as gloss, colour, shape, roughness, surface texture,
shininess, and translucency (Leemans et al., 1998; Jahns et al., 2001; Hatcher et al., 2004;
Briones and Aguilera, 2005; Briones et al., 2006; Altimiras et al., 2007; Afoakwa et al., 2008a).
Knowledge of tempering effects on product texture and appearance attributes can have
significant commercial implications.

With recent innovations and growth in chocolate confectionery industry, understanding the
factors influencing chocolate microstructure, texture and appearance would be of value in
predicting changes in quality. This study was therefore aimed at investigating effects of
tempering and fat crystallizations behaviors on microstructure, mechanical properties and
appearance in dark chocolates varying in particle size distribution.

2. Materials and methods

2.1. Materials

Cocoa liquor of Central West African Origin was obtained from Cargill Cocoa Processing
Company (York, UK); sucrose (pure cane extra fine granulated) from British Sugar Company
(Peterborough, UK); pure prime pressed cocoa butter and soy lecithin from ADM Cocoa Limited
(Koog aan de Zaan, Netherlands) and Unitechem Company Ltd. (Tianjin, China),respectively.
The recipe, formulation and production of samples have been described previously (Afoakwa et
al., 2007b). Chocolates were formulated with total fat of 35% (w/w) from sucrose, cocoa liquor,
cocoa butter and lecithin. Experimental samples (5 kg batch for each formulation) were produced
by mixing sucrose (40.8%) and cocoa liquor (53.7%) in a Crypto Peerless Mixer (Model K175,
Crypto Peerless Ltd, Birmingham, UK) at low speed for 2 min and then at high for 3 min, then
using a 3-roll refiner (Model SDX 600, Buhler Ltd., CH-9240 Uzwil, Switzerland) to a specified
particle size (D90:18 ± 1 lm, 25 ± 1 lm, 35 ± 1 lm and 50 ± 1 lm) conducting particle size
analysis, during refining, to ensure D90 values. The refined chocolates were melted at 50–55 _C
for 24 h and the chocolate mass conched in a Lipp Conche (Model IMC-E10, Boveristr 40-42,
D-68309, Mannhein, Germany) at low speed for 3.5 h at 60 _C. Lecithin (0.5%) and cocoa butter
(5%) were added and then conched at high speed for 30 min to effect adequate mixing and
liquefaction. Samples were kept in sealed plastic containers at ambient (20–22 _C) and moisture
and fat contents determined using Karl Fischer and Soxhlet methods (ICA, 1988) and (ICA,
1990).

2.2. Determination of particle size distribution

A MasterSizer_ Laser Diffraction Particle Size Analyzer equipped with MS 15 Sample

Presentation Unit (Refractive index 1.590) (Malvern Instrument Ltd., Malvern, England) was
used. About 0.2 g of refined dark chocolate was dispersed in vegetable oil (Refractive index
1.450) at ambient temperature (20 ± 2 _C) until an obscuration of 0.2 was obtained. The sample
was placed under ultrasonic dispersion for 2 min to ensure particles were independently
dispersed and thereafter maintained by stirring during the measurement. Size distribution was
quantified as the relative volume of particles in size bands presented as size distribution curves
(Malvern MasterSizer_ Micro Software v 2.19). PSD parameters obtained included specific
surface area, largest particle size (D90), mean particle volume (D50), smallest particle size (D10)
and Sauter mean diameter (D[3,2]).

2.3. Tempering experiment

Samples were incubated at 50 _C for 4 h for melting and tempered using Aasted Mikrovert
laboratory continuous three-stage tempering unit (Model AMK 10, Aasted Mikroverk A/S,
Farum, Denmark). Chocolate was pumped through the multi-stage units and a worm screw drove
the product through the heat exchangers.

Sensors located at specific points in the equipment measured the temperature of both the
chocolate and the coolant fluid at each stage. Based on our earlier work modelling temperature
controls to study tempering behaviour (Afoakwa et al., 2008b), the temperature of each of the
coolant fluids (Zones 1:2:3) were thus set as 26:24:32 _C, 21:19:32 _C and 18:16:32 _C,
respectively for attaining the under-tempered, optimally-tempered and over-tempered regimes.
The degree of pre-crystallisation was measured using a computerized tempermeter (Exotherm
7400, Systech Analytics, Neuchâtel, Switzerland) and a built-in algorithm provided the
tempering curves and temper readings in chocolate temper index (slope), corresponding to
optimal temper (slope 0), undertemper (slope 1.0) and over-temper regimes (slope _1.0). The
principle of this method has been described by Nelson (1999).

Chocolate from the three regimes were moulded using plastic moulds: 80 mm length; 20 mm
breadth; and 8 mm height. The final products were allowed to cool in a refrigerator (5 _C) for 2 h
before de-moulding onto plastic trays and conditioned at 20 ± 2 _C for 14 days before analysis.
Triplicate measurements were taken for each product composition and the mean values recorded.

2.4. Texture measurements

Mechanical properties of chocolates (hardness and stickiness) were measured using TA-HD Plus
Texture Analyzer with a penetration probe (needle P/2) attached to an extension bar and a 50 kg
load cell and a platform reported by Afoakwa et al. (2008a). Maximum penetration and
withdrawal forces through a sample (80 _ 20 mm, depth 8 mm) were determined with 8
replications at a pre-speed of 1.0 mm/s, test of 2.0 mm/s, post speed of 10.0 mm/s, penetrating 5
mm at 20 _C, converting mean values of the penetration force exerted by the 50 kg load cell into
hardness (g force) and the withdrawal force with time into stickiness (g force s) data,
respectively using XT.RA Dimension, Exponent 32 software (Stable Micro Systems, Godalming,
Surrey, UK).

2.5. Colour and gloss measurements

HunterLab MiniscanTM XE Colorimeter Model 45/0 LAV (Hunter Associates Inc., Reston, VA)
calibrated with white ceramic reference standard was used. Colour images of chocolate surfaces
were converted into XYZ tristimulus values, which were further converted to CIELAB system:
L*, luminance ranging from 0 (black) to 100 (white); and a* (green to red) and b* (blue to
yellow) with values from _120 to +120. Information was obtained using a software algorithm
(Matlab v. 6.5; The Math-Works, Inc., Natick, MA): hue angle (h_) = arctan (b*/a*); chroma
(C*) = [(a*)2 + (b*)2]½. Mean values from five replicate measurements and standard deviations
were calculated. Gloss of chocolate surface was measured using the multiple angle Tricor Gloss
meter (805A/806H Gloss System, Elgin, IL). Reflectance was measured at an incidence light
angle of 85_ from the normal to the chocolate surface, in accordance with ASTM method D523.
A polished black glass plate with a refractive index of 1.567 was used as standard surface
(ASTM, 1995) and given a gloss value of 200. Gloss was reported as gloss units (GU) based on
determinations (in triplicate) at six positions along a chocolate sample. As a reference, a surface
with a gloss value less than 10 GU is considered a low gloss surface (BYK, 1997; Briones et al.,
2006).

2.6. Image acquisition and capture

A colour digital camera (Canon Powershot, Model A70, MA, USA) was mounted on a stand
inside a large box with internal black surface impervious to light. Images of the optimally
tempered, under- tempered and over-tempered samples were captured before storage and after 14
days in storage. The iris was operated in manual mode, with the lens aperture at f = 8 and speed
1/20 (no zoom, no flash) to achieve high uniformity and repeatability. The camera was gray
balanced before each imaging session. Uniform diffuse lighting was used to illuminate the
samples. The lighting system consisted of four CIE source D65 lamps (60 cm length and 18 W;
Model TLD/965, Philips, Singapore) placed above the sample at a 45_ angle to maximize diffuse
reflection responsible for colour. The angle between the camera lens axis and the sample was
around 90_ to reduce gloss. A Kodak gray card with 18% reflectance was used as a white
reference to standardize the illumination level. The gray-level image (1600 _ 1200 pixels) of this
card was divided into 192 blocks, each one of 100 _ 100 pixels. After calibration, samples were
placed in the field of view of the camera and an image of 1600 _ 1200 pixels (approximately
covering the whole area of the tablet) was acquired and stored in JPEG (joint photographic
experts group, a standard for compressing digital photographic images) format of high resolution
and superfine quality.

2.7. Microstructural determinations

Chocolate samples were characterised using stereoscopic binocular microscope (Nikon, SMZ-
2T, Tokyo, Japan) equipped with a variable removable lens. Micrographs (coloured images)
were captured using a digital camera (Model 2.1 Rev 1, Polaroid Corporation, NY, USA) and
observed using Adobe Photoshop (Version CS2, Adobe Systems Inc. NJ, USA). Triplicate
experiments were conducted capturing 6 images per sample, and micrographs representing the
surface of each temper regime captured and presented.Samples were then sectioned (cut) into
two pieces using a knife and the internal microstructures observed.

2.8. Experimental design and statistical analysis

Two experimental variables comprising temper regime and PSD were used. Other variables
including refiner temperature and pressure, conching time and temperature were held constant. A
3 _ 4 factorial experimental design was used comprising:
(i) Temper regime: optimal temper, under-temper and overtemper. (ii) PSD (D90): 18, 25, 35 and
50 lm. Statgraphics Plus 4.1 (Graphics Software System, STCC, Inc,Rockville, USA) examined
mechanical properties (hardness and stiffness) and appearance (colour [L, C*, h_] and gloss)
using twoway analysis of variance (ANOVA) and multiple comparison tests to determine effects
of factors and their interactions. Tukey multiple comparisons (95% significance level)
determined differences between levels. All experiments were conducted in triplicates and the
mean values reported.

3. Results and discussion

3.1. Particle size distribution of dark chocolates

These findings (Fig. 1), previously reported (Afoakwa et al., 2008a), show volume histograms
consisting of narrow (18 lm PS) and wide (25 lmPS) bimodal and narrow (35 lmPS), and wide
(50 lm PS) multimodal size distributions. This PSD range 18– 50 lm using D90 values (>90%
finer) covers optimum minimum and maximum sizes with direct effects on texture and sensory
character in manufacture (Ziegler and Hogg, 1999; Beckett, 2000). Data from the PSD as
previously described (Afoakwa et al.,2008a) showed variations in specific surface area, mean
particlevolume D(v,50), Sauter mean (D[3,2]) and mean particle diameter (D[4,3]) with
increasing D90 particle sizes. Specific surface area (SSA) was inversely correlated with the
different component of PSD. Similar inverse relationships of SSA with all the other components
of PSD have been reported (Beckett, 1999; Ziegler and Hogg, 1999; Sokmen and Gunes, 2006).
Beckett (1999) concluded largest particle size and solids specific surface area are the two key
parameters for chocolate manufacture. The former determines chocolate coarseness and textural
character, the latter with desirable flow properties. Fat contents of the products were 35 ± 1%
and moisture within the range of 0.90–0.98%.
3.2. Fat crystallisation behaviours during tempering of dark chocolate

Four different temper regimes (untempering, under-tempering, over-tempering and optimal

tempering) were characterised (Fig. 2) each with its unique characteristic crystallisation
behaviour. In optimal tempering, the temperature of the chocolate remained constant for
sometime during cooling, to initiate formation of stable fat crystals. The crystallisation heat
released was then balanced by an equal amount of cooling energy causing the growth of stable
crystal nuclei in adequate amounts, which during post-tempering conditioning mature to effect
shelf stability of the product. The temperature of the chocolate dropped further when the liquid
cocoa butter was transformed into solid crystals resulting in solidification of the products (Fig.
2). Beckett (2000) reported that properly tempered chocolate shows formation of Form V, the
most desirable polymorphic form which confers appropriate product snap, contraction, gloss and
shelf-life characteristics.

Under-tempering (insufficient tempering) was caused by the relatively higher temperatures

released between the multi-stage heat exchangers during tempering. The process caused
development of more crystallisation heat within the product during solidification, effecting quick
cooling, as more liquid fat was transformed quickly into solid form, resulting in the formation of
very few stable fat crystal nuclei (Fig. 2). Distinct increase in temperature was observed at the
beginning of the crystallisation, which declined again after reaching a maximum point where
most of the stable crystals formed were re-melted prior to cooling. Untempered chocolate,
produced no stable fat crystals as the heat exchange system generated higher crystallization heat
during cooling, resulting in quick cooling of the completely melted product with no inflexion
point for stable fat crystal formation (Fig. 2). Beckett (2000) explained that the crystallisation
processes in both untempered and under-tempered chocolates lead to the formation of unstable
Form IV polymorph, which later transforms into more stable Form VI polymorph during storage.
Preliminary studies showed that untempering and under-tempering regimes exhibits different
crystallisation behaviours but results in similar unstable fat crystal nucleation and growth, with
similar associated storage polymorphic transformations and defects in products. Storage of the
under-tempered products under ambient temperature (20–22 _C) for 14 days of conditioning
induced blooming in samples, effecting various quality changes in the products as reported in
this study. Products from under-tempering regime were used in this study.
Over-tempering occurred when relatively lower temperatures were exchanged between the multi-
stage heat exchangers of the tempering equipment, causing significant part of the liquid fat to
withdraw from the continuous phase of the chocolate, and transformed
into solid form when less liquid fat was available for pumping the product. The process released
little crystallization heat during cooling, rendering a rather flat and slow cooling curve (Fig. 2).
This crystallisation process results in too many small stable seed crystal formation leading to
reduced strengths in the polymorphic stabilities of the fat crystals formed during the process
(Talbot, 1999). As a substantial part of the phase transition (from liquid to solid) took place
before the chocolate reached the mould, less contraction occurred in the mould, leading to
demoulding problems with defects in final product quality and storage characters (Hartel, 2001;
Lonchampt and Hartel, 2004).

3.3. Effect of temper regime and PSD on mechanical properties

Hardness showed an inverse relationship with particle sizes, with significant reductions at all
temper regimes, and greatest in the under-tempered (bloomed) products (Fig. 3). Hardness of the
optimally-tempered products decreased from 5318 g with 18 lm PS to 4259 g at 50 lm. Similar
trends in hardness were noted with the over-tempered samples, decreasing from 6064 g with 18
lmPS to 4651 g at 50 lm, and from 6533 g with 18 lm PS to 5459 g at 50 lm in the bloomed
products (Fig. 3), suggesting differences in hardness with varying PS at all temper regimes.
Particle sizes have been noted as an important parameter in the hardness of fat crystal networks
in many confectionery products (Narine and Marangoni, 2002; Campos et al., 2002; Marangoni
and Narine 2002; Pérez- Martínez et al., 2007). Earlier studies showed inverse relationships of
hardness in tempered dark chocolates with particle sizes at varying fat and lecithin levels
(Afoakwa et al., 2008a), attributed to the relative strengths of their particle-to-particle
interactions (Campos et al., 2002; Afoakwa et al., 2008c). Do et al. (2007) also reported
consistent reductions in hardness (texture) of milk chocolates with increasing particle sizes.
The results showed that the under-tempered products had the greatest hardness (texture),
attributable to the re-crystallisation process undergone by the fat in the under-tempered
chocolates resulting in intense hardening of products. This trend in hardness was followed by the
over-tempered samples with the optimal tempered products possessing relatively lesser hardness
levels, suggesting over-tempering of dark chocolates leads to increased hardness of samples at all
PS as compared to their respective optimally-tempered products.
Chocolate stickiness showed an inverse relationship with particle sizes at all temper regimes, and
the greatest trends were noted in the over-tempered products (Fig. 4). Stickiness of the
optimallytempered products decreased consistently from 380.67 g with 18 lm PS to 325.25 g at
50 lm. Likewise, the levels of stickiness in the over-tempered samples decreased from 447.92 g
with 18 lm PS to 365.10 g at 50 lm, and from 336.86 g with 18 lm PS to 309.20 g at 50 lm in the
bloomed products (Fig. 4), explaining that the over-tempered products had the greatest stickiness
levels, followed by the optimally tempered products with the bloomed samples having the least.
Narine and Marangoni (2001) noted that stickiness of confectionery gives information about
deformability related to oral sensory characters. Analysis of variance (ANOVA) suggested
significant differences (P <
href="http://img03.blogcu.com/images/a/c/a/acarserpil/3_1243391246.jpg">
3.4. Effect of temper regime and PSD on colour and gloss

Lightness (L*), chroma (C*) and hue (h_) followed similar trends with varying PS at all temper
regimes (Table 2). Significant (P <>

As well, the blooming caused great reductions in C* and h_ in the under-tempered products at all
PS (Table 2). Hutchings (1994) stated that L*, C* and h_, respectively represent food diffuse
reflectance of light, degree of saturation and hue luminance, which are dependent on particulate
distribution, absorptivity and scatter-ing factors or coefficients. In a densely packed medium,
scattering factor is inversely related to particle diameter (Saguy and Graf, 1991). Chocolates with
varying particle sizes differ in structural and particulate arrangements influencing light scattering
coefficients and thus appearance (Afoakwa et al., 2008a).

Similar decreasing trends in L* were noted in both tempered and over-tempered samples with
increasing PS. However, the over-tempered samples had relatively lower L* values at all PS as
compared to their corresponding optimally tempered products (Table 2).
These suggest that over-tempering reduces the degree of lightness in dark chocolates, effecting
product darkening and thus affecting quality. However, no noticeable effect on C* and h_ were
observed among the tempered and over-tempered products (Table 2). Thus, changes in colour in
dark chocolates were primarily dependent on PS and temper regime. Bloomed dark chocolates
tend to scatter more light, appear lighter and less saturated than over-tempered and optimally
tempered products. The blooming process resulted in higher scattering coefficients, with
subsequent paleness (whitening) - higher L* values. Hartel (1999) reported that the whitish haze
in bloomed chocolate is caused by the dispersion of light of fat crystals. Similar effects of PS on
the degree of whitening during blooming have been reported (Altimiras et al., 2007).Colour of
foods may be affected by various optical phenomena among them scattering and surface
morphology, therefore an accurate understanding of the influence of appearance on measured
colour is essential.
Gloss relates to capacity of a surface to reflect directed light at the specular reflectance angle
with respect to the normal surface plane (ASTM, 1995). Significant (P <>

ANOVA showed that PS and temper regime both significantly (P <>3.5. Effect of temper regime
on product image

Digital images of dark chocolates (18 lm PS) were assembled to show surface appearances of
optimal, under- and over-tem pered products before and after the 14 days conditioning (Fig. 5).
Initially surface appearances were similar and smooth but after 14 days, clear differences were
apparent. Optimally and overtempered chocolates maintained their characteristic glossy
appearance and dark brown colour but the under-tempered samples had bloomed, with
appearance of surface whitish spots, rendering them dull and hazy in colour (Fig. 5). Similar
increases in whiteness in under-tempered (bloomed) chocolates have been reported (Lonchampt
and Hartel, 2004, 2006; Altimiras et al., 2007). Hartel (1999) explained this phenomenon as re-
crystallisation of fats from a less stable Form IV to a more stable Form VI polymorph, with
changes in light dispersion on small surface fat crystals (>5 lm), consequently impacting on both
appearance and textural attributes. Fat bloom development, mechanisms and effects on chocolate
appearance, quality and marketability has been extensively studied (Bricknell and Hartel, 1998;
Ali et al., 2001; Hartel, 2001; Timms, 2003; Walter and Cornillon, 2001, 2002; Lonchampt and
Hartel, 2004, 2006; Altimiras et al., 2007; Smith et al., 2007).

3.6. Effect of temper regime on microstructure

Microstructural examination using stereoscopic binocular microscopy after the 14 days
conditioning showed clear variations in both surface and internal peripheries of products from
varying temper regimes (Fig. 6). Over-tempered products had relatively darker surfaces and
internal appearances than optimally tempered confirming the reported relative differences in L*
(Table 2). Undertempered products showed both bloomed surface and internal periphery with
large whitish, and distinct smaller brown spots (Fig. 6). The observed whitish appearance on
surfaces and internal peripheries appear to be mixtures of re-crystallised fat and sugar crystals,
and the small brown spots, cocoa solids. Lonchampt and Hartel (2004, 2006) suggested these
whitish spots were primarily sugar crystals and cocoa powder and nearly devoid of fat. This
difference in interpretation is the subject of further studies.

4. Conclusion

Fat crystallisation behaviour during tempering of dark chocolate play vital roles in defining the
structure, mechanical properties and appearance of products. Wide variations in mechanical
properties and appearance occurred in products from different PS and temper regimes. Particle
size was inversely related with texture and colour, with the greatest effects noted with hardness,
stickiness and lightness at all temper regimes. Over-tempering caused increases in product
hardness, stickiness with reduced gloss and darkening of product surfaces. Under-tempering
induced fat bloom in products with consequential quality defects in texture, colour and surface
gloss. Micrographs revealed clear variations in surface and internal crystal network structure and
inter-particle interactions among tempered, over-tempered and under-tempered (bloomed)
samples. Blooming caused whitening of both surface and internal periphery of products with
consequential effects on texture and appearance. Hence, attainment of optimal temper during
tempering (pre-crystallisation) of dark chocolate is vital to the desired texture and appearance of
products, as both over-tempering and under-tempering result in quality defects affecting
mechanical properties and appearance of products.

Acknowledgements

This study was co-funded by the Government of Ghana and Nestlé Product Technology Centre
(York, UK). The sponsors are gratefully acknowledged for the Research Support. We also wish
to thank Drs. Steve Beckett, Angela Ryan, John Rasburn and Angel Manez (Nestlé PTC, York)
for useful technical discussions.

Posted by Serpil Acar at 10:11 AM 0 comments

Labels: DARK CHOCOLATE, Fat Bloom, FAT CRYSTALLISATION BEHAVIOUR, particle
size distribution, Tempering

FAT BLOOM AT CHOCOLATE

1.Introduction
Fat bloom is a common problem in the confectionery industry. It is most often seen on chocolate,
but can also appear on the surface of biscuits. The problem can cause very significant product
losses. This is not because there is a contamination or specific quality issue. It is mainly because
the visual characteristics become unacceptable, due either to loss of gloss or to the appearance of
a white "frosting" at the surface of the product. The white frosting (Figure 1) is sometimes
mistaken for mould growth but quite definitely is not.
It is a surface re-crystallisation of fat caused generally by migration.

Figure 1: White "beta-form" bloom ("frosting") on the chocolate of a half-coated biscuit

A more severe situation in chocolate can occur after some time, where the chocolate becomes
grainy, crumbly and with no gloss or sensory appeal (Figure 2). This happens throughout the
bulk of the chocolate material and is not just a surface phenomenon.
Figure 2: Severe bloom caused by Form VI crystal growths on the surface of chocolate
From what we have said above it becomes plain that there are at least two bloom effects.The bloom
that is a characteristic of chocolate (Figures 2 and 3) may be termed Form VI bloom. The bloom shown in
Figure 1 on the surface of chocolate can also appear on the surface of biscuits and even in semi-solid
fats such as butter and fat spreads. This type is caused by a re-crystallisation of fat and is often
accompanied by a change in crystal morphology. This type may be loosely called "beta-form" bloom. It is
important to understand also that there is more than one mechanism at work. Food products are not
static entities, they are quite dynamic and this creates partly the phenomenon of shelf life.
The properties that we have to consider are, in the main, thermodynamic ones.
Multiplephase foods, such as butter-cream-filled biscuit bars with a chocolate coating, create conditions
where thermodynamic change is positively driven. Entropy is not a term just for physicists, because in
making such foods the processes must address free energy change if a stable, long shelf life is to be
achieved. The manufacturing process must attempt to achieve a stable low energy state for the
components. If it does not then you end up, for instance, with partially crystallised fat in the insulated
environment of palletised finished goods. Why is this a problem? We will explain this in the following
text.
Figure 3: Form VI bloom in chocolate causes major structural change

2. Fat Crystallisation

All natural fats are mixtures of triacylglycerols (TAG). Each pure individual TAG will have a different
crystallisation temperature. However, when mixed this causes the fat to have a wide range of
temperature over which crystallisation occurs. Thus you obtain the phenomenon of solid/liquid ratios in
fat mixtures. These ratios can be determined using pulsed nuclear magnetic resonance (pNMR) and
some data is shown in Figure 4. It can be seen from this data that, if a product is made using one or
more of the fat mixtures and then
displayed for sale, the temperature of the display area will affect the state of the fat in the product. Thus
as temperature cycles, so does the liquid/solid fat ratio. More importantly, the ratio will often be
different in each fat phase at the given temperature, creating imbalances across the different food
matrixes, e.g. biscuit dough, cream filling and chocolate coating in a biscuit snack. We shall come back to
this situation.
Figure 4: Solid Fat Content by pulsed NMR - typical Values

Crystallising fat systems are usually polymorphic. In most cases this is represented by 3 crystal forms
termed _ (alpha) , _' (beta prime) and _ (beta), in increasing thermodynamic stability and increasing
melting point. Not all fats can move freely from _ to _ because this depends on the ability of molecules
to pack closer together. Some can, like cocoa butter; some cannot, like Salatrim (Benefat) which stays in
the _ form. There is further complexity in that certain TAG types (cocoa butter is very rich in these
symmetrical TAGs which have
an unsaturated fatty acid at the middle position) create the possibility for up to 6 crystal forms. The
chocolate tempering process is designed to stimulate cocoa butter to crystallize in Form V. This process
involves maintaining the temperature at around 29C-31C after a controlled cooling process.
Crystallising fat gives up heat energy (its heat of crystallisation). As the process progresses to more
stable forms a certain amount of heat energy might be required to begin the process. Thus if a fat has
reached _' and is then stored at, say, less than 20C, it is unlikely to progress to _ form, unless it is heated
to above 25C. This point brings us back to two issues mentioned above: cycled temperature storage and
palletised storage.
Cycled temperature storage applies significant energy stress to a product. This often results
in a change of crystal form. In addition, during cycling temperatures, the crystalline fat can begin to
separate from the liquid phase and undergo individual changes. For palletized storage of poorly cooled
product, the crystallising fat yields heat that cannot escape due to the insulating nature of palletised
boxed products. This excess heat can raise the internal temperature by 2-3C. This can be sufficient to
cause fat/chocolate melting and recrystallisation.
3. Liquid Fat Migration

In a crystallised fat, the liquid fat component is dispersed in and around the solid crystal clumps. The
mobility of this liquid will to some extent depend upon the three-dimensional structure of the solid
crystal network. At a given temperature, the liquid component will have a certain composition. As the
temperature rises the amount of liquid fat will increase and its TAG composition will change.

In a single-matrix system, the consequence of this change may be nothing. Alternatively, it may trigger
certain TAGs to separate or fractionate from the main bulk of the fat. This will lead to the growth of
larger crystals over time that may be in the _ form. In a system with more than one matrix, each
containing a different fat, the picture becomes complex. There are different liquid/solid ratios, maybe
different total fat contents and different TAG compositions. All these points apply their own
thermodynamic pressure for the liquid fat components to move or migrate between the matrixes.
Although this fat migration may not be a problem, it usually does create problems.

As the liquid fats move between matrixes they mix with other liquid fat phases and thus change their
composition. This may cause a change in the solid fat solution, i.e. more solid fat might dissolve at a
given temperature, causing softening. In addition, the balance of the solution composition might change
sufficiently to make other TAGs less soluble, causing them to crystallise out. The effect of temperature
cycling must also be superimposed on this process. Different effects can be seen in some products when
they are stored at different
constant temperatures (e.g. 22C or 25C) because the composition of the liquid fat phase varies with
temperature.

4. Bloom Types

We have described above a number of dynamic processes that happen in products containing significant
amounts of TAG. So how are these related to fat bloom? The visual effect of fat bloom is caused by
crystal growth or a change in the crystal morphology after the product has been made (i.e. during shelf
life). Let us now consider the Form VI and beta-form types of fat bloom.
Figure 1 shows a white frosted, beta-form bloom growth on the surface of chocolate. The crystals that
are growing look (in close-up) very like diamond clusters. The finer structure is shown in Figure 5. This
contrasts greatly with the leaf-like structures of classic Form VI bloom shown in Figure 6. This beta-type
bloom is migration related and can be particularly bad where the migrating components come from a
palm oil based dough fat. This type of bloom is rich in symmetrical TAGs of the POP and POSt type (P =
palmitic acid, O = oleic
acid, St = stearic acid). Form V to Form VI inhibitors will not stop this bloom occurring because it is a shift
in solid solution caused by the migrating palm oil TAGs. It is interesting to note that if the chocolate-
coated product is stored at a constant 22C this bloom is predominant. However, if the storage
temperature is a constant 25C then Form VI bloom occurs.
Figure 5: Beta form bloom crystals on surface of chocolate (these can also appear on biscuits)
The white frosting can be generated directly on the surface of high-fat baked goods, such as biscuits
through fat separation and crystal growth. These biscuits can show the effect whether half coated with
chocolate or not. The effect is more prevalent where palm oil is a major part of the fat blend in use. It is
a consequence of the TAG composition of palm oil, which contains significant amounts of POP/POSt and
PPP. Palm oil readily fractionates under certain conditions to yield fast growing crystals in the _ form.
This problem can be
caused by over-cooling (shock-cooling) the product as it leaves the oven and packaging point. A certain
amount of _ crystal is formed and an unstable situation exists.
Transformations over the next 24 hours often yield a bloomed surface. This bloom is not always
permanent and can sometimes be removed by warming the product to 25C for a short period of time. A
similar effect can be caused in the biscuit where a chocolate coating or inclusion (e.g. chocolate chips in
cookies) may act as a very efficient "sink", via migration, for the liquid fat fraction. The consequence in
time is a bloomed visual effect as the more solid TAGs recrystallise with growth of crystal size.
Another effect caused by overheating the surface of, for example a biscuit, is that the fat melts and
liquid fat is drawn to the surface. This then cools quiescently and forms large crystal clumps that appear
as bloom. This bloom is usually permanent. Such effects are caused, for example, by the hot plate, pack,
end sealers overheating the packaging. The end biscuits in a pack then exhibit a "staining" effect, caused
by large fat crystals.

Figures 2 and 3 show a particularly severe case of Form VI bloom in chocolate. The chocolate bar had a
fat-cream filling and had been exposed to temperatures cycling between 18C and 28C over a period of 8
weeks. The chocolate has completely destabilized and the surface is covered with crystal growths. More
particularly the whole structure has transformed to Form VI (confirmed using X-ray diffraction) and has
become open, fragile and powdery. This type of bloom can be reduced, but not always eliminated, using
Form V to VI inhibitors.
Figure 6: Leaf-like structures of classic Form VI bloom

5. Bloom Prevention

The title of this section is easy to write, the doing of it is not so easy. As we said earlier, foods are
dynamic systems and undergo significant change during shelf life. If we are to prevent bloom then we
have to address thermodynamic change. That means either
ensuring the food product has a low free energy state (i.e. is stable to further physical change), or,
introducing some means of interrupting change by perhaps blocking it. The former method is used
extensively by the fat spreads and chocolate industries. The product is made under optimum
temperature conditions to ensure that the correct fat crystal form is generated. The product is then
given sufficient time to "temper" under controlled temperature storage before it is fully packaged,
boxed and palletised for delivery. This regime ensures that, for spreads the _' fat crystal form
predominates and is stabilised, while for chocolate, the latent heat of crystallisation is removed below
25C to ensure a stable Form V crystal network is created. This approach does, to a large extent, assume
that the product will not undergo large, post-production, temperature fluctuations during transport,
sale and use/storage by the consumer.

However, it is a fact of life that time costs money and any means of speeding up product flow and
increasing volume is enthusiastically sought by manufacturers (or at least by their management!). In
addition, environmental temperature for product storage can be advised but not always ensured. In
these situations some means of blocking crystal change can be advantageous. Milk chocolate contains a
significant amount of butterfat and, because butterfat creates a strong eutectic with cocoa butter, the
resultant product is much softer than plain chocolate. Milk chocolate rarely if ever undergoes Form VI
bloom. The reason for this is the composition of butterfat contains a large range of TAG structures and
molecularweights. This is due to the presence of significant amounts of fatty acids from C4 to C14. These
serve to block the move from Form V to Form VI because, as they co-crystallise with cocoa butter TAG,
the packing density of the crystals does not permit the thermodynamic change. The butterfat TAG also
cause a change in the solid solution and thus a softer product. Both these effects reduce the incidence of
bloom. This action of butterfat can (and is) harnessed to reduce the occurrence of bloom in plain
chocolate. Butterfat can be added at a low level where softening of the chocolate is not significant but
the effect on crystal form change is very significant.

The blocking of V to VI crystal form change in chocolate with butterfat is accompanied by a strong
eutectic; in addition butterfat currently costs more than cocoa butter. Partly in response to this, some of
the special (confectionery) fat suppliers have designed bloom inhibitors as vegetable fat additives to
chocolate. It is important to recognise that these additives have to form part of the current legislated
limit of 5% added vegetable fat in chocolate. However, the composition of these fats is such that a range
of TAG structures containing fatty acids from C10 to C18 is introduced into the cocoa butter. These act
to inhibit the re-crystallisation of cocoa butter TAG in Form VI.
Form V to Form VI inhibitors such as described above do not stop the beta-form bloom.
This is because beta-form bloom is mainly a consequence of re-crystallisation and crystal growth
following transformation from _' fat crystal. This type of bloom is much more difficult to address and
arguably is much the most prevalent. Prevention here is one of understanding the product makeup, the
process temperatures and times, and the compatibility of adjacent fats where the product has more
than one component. This last point is imperative when considering shelf life of the product ex factory.
Compatibility of adjacent fats is necessary because fat migration will take place. Noncompatibility will
cause changes in the fat phase balance resulting often in recrystallisation at the product surface (as
described above). Migration can be limited by the use of sprayon barriers or the use of fats that are
highly nucleating on cooling. In the former case, spray-on barriers can be useful for example in chocolate
shells that are to be filled with nut praline. In the latter case, the fats (sometimes called fractal fats),
when cooled from the melt, create many nuclei that grow to relatively small dimentions, rather than fats
that form few nuclei but larger crystals. The effect is to form a very efficient three- dimensional
structure that holds liquid fat very efficiently, reducing the rate of migration. These fats must be _'
stable.
Process considerations must include cooling the product at an appropriate rate so that resulting crystal
forms are stable and not prevalent to transformation. Thus cooling a baked product too rapidly (say
from 30C to below 14C) often results in retention of some _ crystal.This will move to _' crystal on
standing, a condition that can cause temporary surface bloom. Alternatively, packing the product too
hot (>25C) and then providing an insulated environment, such as on a pallet, can cause slow
crystallisation with large crystal growth and separation of solid and liquid fat phases.

6. Conclusion

In conclusion, fat bloom is an expensive problem for food manufacturers and significant care has to be
exercised to reduce its occurrence. Thermodynamic change will happen, but fat bloom is not inevitable
if care is taken over the selection of fats that have to be adjacent in a product. Care must also be taken
in process control and this has to include consideration of all aspects from ingredient mixing, through
packaging, transport and storage.
We have attempted to describe types of bloom and the way in which they can occur in fat based
products. We have discussed the relative complexity involved in trying to limit fat bloom. We believe
that it is important to generate such understanding of products because bloom issues are time-related.
Current food industry structure can involve products being transported over large distances and to
variable ambient climatic conditions. These can include high temperatures and also high humidities. To
these times are added the turnover time of the product, which may be quite different for the large and
small retailer. Getting the
thermodynamic balance right is a challenge for the producer, but the prize is worth the effort in terms of
quality and loss.