NE40902

Bakery Technology and Confectionery

COCOA & CHOCOLATE MANUFACTURE

AP Dr. Mansoor Abdul Hamid
 OUTLINE
 Introduction
 Cocoa Bean Processing
 Cocoa Butter & Replacement Fats
 Chocolate Manufacture
 Confectionery Coatings, Chocolate Replacers, Dietetic
Compounds
 Chocolate Bars & Covered Confectionery

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Introduction
 World cocoa producer

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 Chocolate History
 Cocoa tree (Theobroma cocoa)
 Swedish botanist Linnaeus give the name “Theobroma” –
Food of the Gods – to the genus.
 Mayas of the Yucatan & Aztecs of Mexico cultivated cocoa
long before it was introduced to Europe.
 Montezuma, emperor of the Aztecs, is stated to have
regularly consumed a preparation called “chocolatl” made
by roasting & grinding cocoa nibs - mashed & mixed with
water, maize & spice – Aztec believe cocoa tree was of
divine origin.
 In 16th century “chocolatl” – favourite drink of the Aztec.

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 Chocolate History cont’d
 In 1519, a Spaniard landed in Mexico & amazed by the
“chocolatl”. From this time cocoa was brought out of
America to other part of the world.
 The Spaniards kept secret the cocoa manufacturing
technique for about 100 years from the European.
 In 17th century, secret of preparing “chocolatl” was
uncovered. In 1615, secret was uncovered when Anne of
Austria, a princess of King Philip of Spain married to King
Louis XIII of France.
 In 1650’s chocolate drink was accepted in England & in
1657 chocolate become the drink of the English official.

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 Chocolate History cont’d
 In 1828, C.J. Van Houten, chocolate manufacturer from
Holland invented cocoa press to separate cocoa butter
from the powder. Cocoa products were improved by
addition of alkali.

 Alkalization process has allowed the product to be dry,

saturated & easy to make drink.

 In 19th century, chocolate was further developed when

Joseph Fry found method of mixing cocoa butter with
other ingredients. In 1847, Joseph Fry mixed sugar &
cocoa powder to produce first chocolate in the world.

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 Chocolate History cont’d
 In 1875, Daniel Peters of Switzerland had developed milk
chocolate.
 In 1890, Rudolph Lint introduced conching process to refine
cocoa particles.
 To further improve the chocolate, Lint had added cocoa
butter to produce a new product named chocolate fondant, a
very fine & high quality chocolate.
 Milk chocolate is now popular food in America & Europe.

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 Cocoa Growing Area in Malaysia
 Cocoa planting in Malaysia started in Agriculture Station in
Serdang & Agriculture Research Centre in Silam, Sabah.
 Sabah is largest producer followed by Perak, Selangor,
Pahang, Terengganu & Johor. Between 1970 & 1975 Sabah,
Perak & Selangor were largest producer.
 Cocoa hybrids from Sabah were found to be better which
produce higher yield & resistant to disease.
 In 1960, Malaysia cocoa planting areas were only 577
hectare but increased to 430,000 hectare in 1991 (high price
of cocoa at that time).
 However, areas decreased to 40,000 hectares in 2005.
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 Land Use Changes (LUC) of selected Plantation
Tree Crops in Malaysia (Conversion of lower productivity crops to high
yielding oil palm plantation)

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 Problem of cocoa industry in Malaysia;

 High operational cost

 Cocoa diseases – Cocoa pod borer
 Low yield – most production <1 ton /
ha
 Low quality of cocoa beans – weak
cocoa flavour, strong acidic flavour

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COCOA
 COCOA FRUIT
 Cocoa fruit or usually called cocoa pod
varies in size, shape & colours depending
on types.
 Types – Criollo, Forastero, Amelonado &
Trinitario.
 About 95% cocoa produce in the world –
Forestero & the hybrids.
 Pods change from green to yellow on
ripeness. Some others change from purple
to orange depending on varieties or clones.
 COCOA
 Fresh cocoa beans from ripe cocoa pods of Theobroma
cacao are harvested together with their surrounding
mucilage (pulp), & pile in large heaps for a week or so
(5-6 days) while spontaneous fermentation occurs.
 Microbial succession of native yeasts, lactic & acetic
bacteria acts on the beans & dried.
 Then they are roasted & partly de-fatted by mechanical
pressing. Press cake is then ground & ‘alkalised’ with
potassium carbonate to provide cocoa powder.
 COCOA
Fresh cocoa beans
Fermentation
Flavour precursors
Drying

Dried cocoa beans

Roasting
Chocolate flavours

Fig. 1. Development of chocolate flavour

 Fermentation;

Cocoa beans being fermented Shallow box fermentation in Malaysia

under banana leaves
 Physical changes of cocoa beans
through fermentation process

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 COCOA cont’d
 Main objectives of fermentation are:-

i. To develop flavour precursors

ii. To remove pulp
iii. To stop germination

iv. To ease drying process

v. To stop fat disintegration
 Main objectives of drying;
1. Reduced MC from 60% to 7.5%
2. Kill and stop microbial activities
1. Prolong storage up to 6 - 12 months

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 COCOA cont’d
 Roasting – 3 types
i. Bean roasting
ii. Nib roasting
iii. Liquor roasting
● Purpose of roasting
i. To develop chocolate flavour
ii. Remove unwanted volatile acids
iii. Reduce bitterness & astringency
iv. Reduce moisture
v. Minimize microbial load
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 - Cocoa bean has to undergo
several steps of processing
before it could be produced
into its semi finished (CL,CB,
CP)and final product
(chocolate).
- Step of processing begins at
the cocoa field, fermentory,
grading centre, grinding
factory & lastly to chocolate
factory.

24 Dry cocoa bean processing

 Dry Cocoa Bean Processing

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 3 semi-finished cocoa products – nibs
grind into liquor, cocoa powder and
cocoa butter

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 Dry Cocoa Bean Chocolate

Cocoa powder**

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Problem of Malaysian cocoa powder;
– weak cocoa flavour
- strong acid flavour

Malaysian land is acidic with lower pH as

compared to other cocoa world producer.
This is the main reason why Malaysian cocoa
beans had strong acid flavour and weak
cocoa flavour. Fertilizer in Malaysia generally
added with alkaline components to neutralize
the acid but yet not really settle the problem.
 Fertilizer management

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Alkalization Process
Alkalization – Alkaline added process for
neutralizing of acid in cocoa. At the same
time this process has several advantages;
- improved cocoa flavour
- produced range of colour

Malaysian Food Act and regulation 1985 -

Regulation 278 (2b) mentioned cocoa / cocoa powder
shall not contain in its water- free and fat-free content more
than 10.5% of total alkalinity calculated as KCO3 and 12.5%
ash.
Malaysian cocoa butter is the best in the world
BUT worst in cocoa powder quality.
Alkalization - conditions need to consider;
1. Type of alkaline agent (KCl, NaCO3 etc.)
2. Concentration of alkaline (0.1% up to 50%)
3. Agitation speed (low – high speed)
4. Reaction time (30 – 120 min)
5. Reaction temperature (room temp. - 75C)
6. Pressure (1 atm – vacuum)
7. Ratio cocoa powder to alkaline solution (1:3,
1:4 etc.)

Every combination of condition give different

quality in term of:
- Colour, pH, moisture content and flavour
profile
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 Cocoa beans Cocoa butter

37 Cocoa liquor Cocoa powder

 Cocoa nibs

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 Cocoa Butter
 Natural fat of cocoa bean (cocoa nib).
 Cocoa butter has several unique qualities:
- has narrow melting range, just below normal human
body temperature: it tends to stay hard until it is very close
to body temperature, & then melts rapidly, carrying &
releasing flavours on the palate.
- sets a brittle consistency at normal room temperature: if
cocoa butter were not brittle, chocolate would not have its
characteristics snap.
- contracts significantly upon setting; it is the contraction of
cocoa butter as it crystallizes that makes it possible to
release chocolate easily from moulds once it is set.
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 Cocoa Butter cont’d
 Cocoa butter, obtained from hydraulic expression of cocoa
nibs, is a light yellow fat, exhibiting brittle fracture below
20oC, a fairly sharp complete melting point about 35oC, with
an incipient fusion or softening around 30-32oC.
 The completely liquid fat displays a marked tendency to
supercool, a fat that must be taken into account in the
process of chocolate enrobing & molding.
 Cocoa butter composed of a number of glycerides of stearic,
palmitic, and oleic fatty acids with small proportion of
linoleic.

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 Cocoa Butter Replacement Fats
 Equivalent Fats (CBE)
- has all the physical & chemical properties of cocoa butter
but has its constituent glycerides derived from sources other
than cocoa bean, eg. palm oil.
 Substitute Fats (CBS)
- bears no resemblance to cocoa butter but can be used with
some degree of success when mixed with small amounts
with cocoa butter or chocolate. Cheaper but quality is
inferior to cocoa butter.
- produced from coconut, palm kernel, other seed & nut oils.
- classified as CBS laurics & CBS nonlaurics

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 Chocolate Ingredients
 Chocolate consists of very small particles (18-35m) of cocoa, milk &
sugar, which are randomly dispersed in fat phase, cocoa butter & milk
fat.
 These particles do not dissolve in the continuous phase but rather mixed
in a randomly manner.
 Basic ingredients:
- cocoa nibs
- cocoa liquor
- sugar or other sweeteners
- cocoa butter
- butter fat (oil)
- milk powder
- milk crumb
- emulsifiers
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 Cocoa butter Sugar Milk powder

43 Cocoa liquor Cocoa powder

 Quality of Chocolate
 Recipe composition
- it depends on amount of ingredients used in the recipe.
● Sugar composition
● Amount & type of fat
- 2 types: cocoa butter & milk fat
- lower fat content means lower quality
- max. CBS < 20% (Malaysia, <5%), high amount may not be
compatible with cocoa butter & may result in fat bloom.
● Quality of raw materials
- chocolate manufacturer have their own specifications
● Cocoa bean
● Processing technology
- technique of roasting, blending, alkalization, conching & tempering
will affect final quality of chocolate.
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 Quality of Chocolate cont’d
 Particle size & its distribution
- acceptable size of chocolate 18 – 35 m.
- if particle too small (< 15 m), particle cannot be detected by the
tongue.
- if size too large (> 35 m), chocolate will give a coarse & sandy taste.

● Crystallization property of fat

- use of other fat in combination with cocoa butter affect the
crystallization property of cocoa butter in chocolate.
- In Europe, CBS is used to replace cocoa butter.
- Optimum storage condition of chocolate is at 16oC with 55% humidity.
Shelf life is 1 year for milk chocolate & 2 years for dark chocolate.

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 Types of Chocolate
(a) Solid Chocolate
i. Milk Chocolate
Ingredients: cocoa liquor, cocoa butter, milk powder, refined sugar,
lecithin, vanilla & salt
ii. Plain/Dark Chocolate
Ingredients: cocoa liquor, cocoa butter, refined sugar, skimmed milk
powder (optional), lecithin, vanilla and salt.
iii. White Chocolate
Ingredients: cocoa butter, refined sugar, milk powder, lecithin, vanilla
and salt.

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 Basic Formulation of Chocolate

Ingredients Milk Dark White

Sugar 35-55% 35-55% 35-55%
Cocoa mass 8-20% 40-60% 0%
Cocoa butter Up to 30% Up to 20% 25-40%
Dry milk Up to 25% 0-8% Up to 25%
products

Total fat content: Normal range 28-36%

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 Types of Chocolate cont’d
(b) Chocolate with filling
i. Tablet or panned chocolate
ii. Bar (enrobed chocolate)
iii. Chocolate with centers – nougat, fat filling, fruits, fondant, truffle,
herbs, marzipan & others (small scale hand made chocolates.

(c) Hollow figure

Chocolate mould can be produced into many shapes &
figures such as flower, animals, eggs, house, etc.
This type of product is usually promoted as seasonal items
for celebration of Christmas, Easter, Valentines, etc.
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 Dry Cocoa Bean Chocolate

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 Mixing
● Cocoa butter, milk powder, refined sugar & part of
cocoa butter are mixed – 5 min, 45oC. At this stage,
only small portion of cocoa butter is added, just enough
to get a paste texture of the mass.
● If the mass were too liquid, it would be difficult to
handle for refining process.
● Lab scale – “end runner mill” with capacity 1-7 kg
● Pilot plant – “Beetz mixer” with capacity 60 kg
● Larger plant scale – bigger capacity machine 1-2 tonne.

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 Refining
● One of the important steps that determine quality of
chocolate.
● Process of breaking up particles of sugar, milk & cocoa into
desired size 18-35 m.
● Particle size influences viscosity & taste of chocolate.
● Factory scale - “five roll refiner”
● Small scale – “three roll refiner”.
● Particle size is measured using Hagmen Block or
Microscrew Meter. A small portion of refined chocolate is
mixed with paraffin oil before measurement is made.

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 Conching
● Refined chocolate mass mixed in a conching
machine for 8-24 hours, 45 – 75oC.
● Remaining cocoa butter is added at this stage.
● During this stage, cocoa butter will coat all the
solid particles of chocolate.
● 2 hours before process ended, lecithin is added
which act as an emulsifier while vanilla and salt are
added to enhance flavour of chocolate.

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 Conching cont’d
● Purpose of conching process are:
- To reduce moisture content to less than 1%
- To evaporate unwanted flavour & volatiles acid such as
acetic acid.
- To produce a chocolate or caramel flavour through a
maillard reaction which is a reaction between reducing
sugar & amino acid at a high temperature & shearing from
the conching process.
- To produce a homogeneous mixture where the fat phase
will coat all the solid particles of sugar, cocoa & milk.

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 Conching cont’d
● For milk chocolate, conching process can be divided into 3
stages:
i. Dry conching for 5 hours at 55-65oC
ii. Plastification for 17 hours at 65oC
iii. Wet conching for 2 hours at 55-45oC
● Examples of conching machine used by the industry –
Petzhold, Thouet, Frisse, McIntyre, Carla Monatanary &
Baruermeister.
● Laboratory scale (capacity 1-7 kg) – Longitudinal Conche &
End Runner Mill.

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 Tempering
● Chocolate contains cocoa butter.

● On cooling cocoa butter forms crystals.

● Cocoa butter has 4 main crystals:  (gamma),  (alpha), ’ (Beta

prime) &  (Beta), depending on temperature it was cooled.
● ,  and ’ crystals are not stable (having low melting point) & crystal
 is the most stable (having a higher melting point).

Crystals form Melting point

 16-18oC

 21-24oC

’ 27-29oC

 33-35oC
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 Tempering cont’d
● Purpose or tempering process is to cool down the chocolate
at a temperature that stable crystal () is formed within a
certain quantity (3-7%) with a relatively small size &
uniformly dispersed throughout the chocolate.
● The formed crystals is known as seeding crystal.
● On cooling, the subsequent crystals formed will follow the
form of the seeding crystals.
● Small crystals size is important for a smooth chocolate
texture. This is achieved by quickly cooling the chocolate.

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 Tempering Process
Melt chocolate (45oC) All crystals melt
  ’ 

Cool down (27-31oC)  crystal will formed with little ’

Reheat (28 - 32oC) To re-melt unstable crystals & leave

only  form with a quantity of 3-7%
(seeding crystals)

Use (28 - 32oC)

Cooling (15-20oC) All crystal will form in  following the

seeds crystals ()
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 Manual Tempering Techniques
1. Hand tempering
- Pour ¾ melted chocolate (45oC) from a bowl onto a
cold marble slab. Work with scrapper until tempering
temperature is reached (27oC for milk choc & 29oC
for dark choc).
- Mix with remaining hot chocolate in the bowl &
stir vigorously to increase the temperature by 1-2oC.
Chocolate is now ready for use.

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 Manual Tempering Technique
2. Hot/Cold water
- A bowl of melted chocolate (45oC) is cooled by
placing it on top of iced water while stirring
vigorously until tempering temperature is reached
(27oC for milk choc & 29oC for dark choc).
- The chocolate is reheated by 1-2oC using a bowl of
hot water while stirring. The chocolate is ready for
use.

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 Manual Tempering Technique
3. Seeding
- Small pieces of chocolate is mixed with a bowl of
melted chocolate (45oC) while stirring until all pieces
are melted. The process is repeated until the
tempering temperature is reached (27oC for milk
choc & 29oC for dark choc).
- The chocolate is then reheated by 1-2oC using some
hot chocolate while stirring. The chocolate is ready
for use.

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 Tempering cont’d
● These are quality of a well-tempered chocolate:
i. A short setting time on cooling (easier to set)
ii. Good glossiness (a very shiny surface)
iii. Heat resistance (high melting point)
iv. Good snap
v. No fat bloom
vi. Easier to remove from the mould.

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 Tempering Machine
 Lab scale – ACMC
 Pilot Plant –Sollich
Minitemper
 Industry – Solich,
Aasted, Baker Perkins,
Freuter

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 Polymorpism in cocoa butter

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 Storage
1. Air conditioned room or refrigerator
- suitable storage temperature 16-24oC.
- storage temperature should be consistent & no
fluctuation in temperature.

2. Air tight container

- chocolate should not be exposed to air humidity.

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 Storage & Processing defects
1. Fat Bloom
- the formation of fat crystals on the surface of
chocolate due to fluctuation in storage temperature.

2. Sugar Bloom
- the formation of sugar crystals on the surface of
chocolate due to storage at high humidity (eg. in a
refrigerator).

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 mouldy

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