Intercontinental Specialty Fats Sdn. Bhd.

Your Preferred Cocoa Butter Alternative Partner

Chocolate / Compound Coating

Formulation & Process

April 2014
Kathy On
Asst. General Manager
History of cocoa and chocolate
- cutting open the cocoa pod

Pod

COCOA MASS

Beans

COCOA POWDER

COCOA BUTTER

Chocolate, Compound Process

 Origin of cacao

7
5
8
1 4 6
9
2 15
3 10 17 19 28
16 18 25
11 20
12
26
Equator 14
23 21 24
13 22 29
27

1 Mexico 6 Haiti 11 Columbia 16 Ivory Coast 21 Equatorial Guinea 26 Malaysia

2 Costa Rica 7 Dominican Republic 12 Ecuador 17 Ghana 22 Gabon 27 Indonesia
Panama Grenada Peru 18 Togo 23 São Tomé 28
Phillipines
3 8 13
Jamaica Trinidad and Tobago Brazil Nigeria 24
Congo Papua New
4 9 14 19 29 Guinea
Cuba Venezuela Sierra Leone Cameroon Sri Lanka
5 10 15 20 25

Chocolate, Compound Process

 Manufacture of cocoa mass,
cocoa powder, and cocoa butter

FRESH BEANS

FLAVOUR
FERMENTATION PRECURSORS

1 Poorly fermented
Acidic
2 Well fermented
Clear, well balanced ROASTING
Over fermented
Off flavours
Unfermented Bean roasting
Very bitter Nibs roasting
Astringent FINAL COCOA 3 Mass roasting
FLAVOUR

Chocolate, Compound Process

 Manufacture of cocoa mass,
cocoa powder, and cocoa butter
ROASTED GRINDING
COCOA NIBS

COCOA MASS

PRESSING

PRESS CAKE PRESS BUTTER

GRINDING DEODORIZE

COCOA POWDER COCOA BUTTER

Chocolate, Compound Process

 Chocolate ingredients

Dark Milk White

 Cocoa solids  Cocoa solids  Cocoa solids
+ Cocoa Butter + Cocoa Butter + Cocoa Butter
+ Cocoa Mass + Cocoa Mass
+ Cocoa Powder + Cocoa Powder  Sugar
 Sugar  Sugar  Milk solids
+ Milk fat
 Milk solids  Milk solids + Whole milk powder
+/- Milk fat + Milk fat + Skimmed milk
+ Whole milk powder powder
+ Skimmed milk + Whey powder
powder + Lactose
+ Whey powder
+ Lactose + Emulsifiers
+ Vanillin, flavours
Chocolate, Compound Process
 Chocolate recipes

Dark Milk White

Sugar 48 44 44
Cocoa mass 40 12
Cocoa butter 12 24 33
Whole milk powder 20 23

100 100 100

Emulsifier : lecithin + + +
Vanillin + + +
Fat content, % 34 36 39

Chocolate, Compound Process

 Making chocolate
COCOA
LECITHIN
BUTTER
SUGAR

COCOA
GRINDING
MASS MIXING CONCHING
COCOA
REFINING
BUTTER
MILK
POWDER
VANILLIN REWORK
LIQUID
CHOCOLATE

SOLID
COOLING MOULDING TEMPERING
CHOCOLATE

STORAGE
Chocolate, Compound Process
Making chocolate
- mixing, refining and fineness
Mixing
 Crystal sugar is added if two-stage
roll refining is done.
 If only one-stage roll refining, sugar
crystal is pre-grind with hammer mills.
 Consistency of the mixed mass to be
adjusted by using more of less fat.
 Mixer fat percentage : 23 – 29%
depending on recipe.
Refining
 Too coarse particles give a sandy
mouthfeel.
5  Too many fine particles result in
a sticky mouthfeel, in addition to
4 flowability.
3  Fineness determined by micrometer.
15 – 25 um Fine chocolate
2
25 – 35 um Enrobing
1 > 35 micron Inclusions

Chocolate, Compound Process

Making chocolate – conching
Purpose of Conching
 Reduction of moisture, and undesired
volatiles.
 Improve flowability.
 Development of fine chocolate flavour.
 Obtain microbial safety.

Conching Phase
 Dry conching – filling of chocolate
powder into the conche (> 55 oC).
 Plasticizing – consistency turns flaky to
viscoplastic. Formation of chocolate
flavour (55 – 95 oC).
Dark chocolate 70 – 95 oC
Milk chocolate 60 – 85 oC
White chocolate < 60 oC

 Liquid conching – Addition of residual

fat, and emulsifiers (approx. 50 oC).

Chocolate, Compound Process

 Types of conche
Large surface, and different
direction of rotation gives
Batchwise Rotary Classic Conche double overthrow effect.

 Conching time 6 – 24 hours.

 Supplier :
Buhler-Frisse (Germany)
Thouet (Germany)
Carle Montanari (Italy)
Petzholdt (Germany) Frisse Double OverThrow Conche, batch 3 – 6 tons.

The turning circles

of the two conching
rotors overlap in the
centre of the conche

Petzholdt HBC-12 Conche, Carle Montanari Homega

Thouet Double Round Conche, batch 3 – 9 tons.
batch upto 12 tons. Conche, batch 4 – 10 tons.

Chocolate, Compound Process

 Types of conche
Batchwise Shear Stream Conche
 Suitable for removing agglomerates.
 Patented rotor/stator shear heads
mounted to the mixer body.
 Shear rate can be adjusted through
motor speed, rotation direction, gap.
 Supplier : Lipp Mischitechnik (Germany)
TRIQUENCE Shear Stream Conche.

Batchwise Short Time Conche

 Short conching time ~ 2 hours.
 Mainly to liquefy chocolate.
 Supplier :
Petzholdt Heidenaur (Germany).
MacIntyre (Scotland)
Caotech (Holland)
MacIntyre Conche. Petzholdt PIV 400. Ball mill Refiner.
Continuous Conching System
 Supplier : Petzholdt Heidenaur (Germany)

Chocolate, Compound Process

 Chocolate needs tempering
STABLE
√ CRYSTALS

Melted cocoa butter

MINUTES HOURS DAYS

MONTHS
VI
32°C
WEEKS  YEARS

30°C
’
22–24°C

 C50 C52 C54 %

UNSTABLE  20°C POP POS SOS 75-85%

 Cocoa butter is polymorphic.
CRYSTALS 14°C  Crystallize in different configurations.
Chocolate, Compound Process
 Chocolate needs tempering

Guideline for tempering

Heat to 45 – 50 oC to melt
1 out of fat crystals.  Dark chocolate = ± 31-32°C
Temperature
Decrease to 27 – 29 oC plus  Milk chocolate= ± 29-30°C
2 high shearing to form both
stable and unstable crystals.  White chocolate = ± 27-28°C
Increase temperature to
3 30 – 32 oC to melt out  Chocolate with nuts = ± 25-26°C
unstable crystals.

1 2 3

Time

Chocolate, Compound Process

Chocolate needs tempering

 Determine tempering
degree using temper meter.

(1) Under tempering

(2) RIGHT tempering

(3) Over tempering

Chocolate, Compound Process

 Temper meter – Temper curves

UNDER TEMPERING RIGHT TEMPERING OVER TEMPERING

Chocolate, Compound Process

 Under & Over crystallization

Under tempering  under crystallization

When ? Results ? Temperature
 Not enough beta crystals.  Lower working viscosity.
 Temperature too high.  Loss of gloss and risk of fatbloom.
 Insufficient shear.  Increased finger sensitivity.
TEMPERING
 Reduced shrinking power.
 Unstable spots.

Over tempering  over crystallization Time Shear

When ? Results ? Movement
 Too much beta crystals.  Higher working viscosity (=thicker).
 Temperature not  Layer thickness of end product.
sufficiently high.  Rough crystals and loss of gloss.
 Too much shear.  Risk of defects for ie. air bubbles. NO. OF
 Reduced shrinking power. CRYSTALS

Chocolate, Compound Process

 Chocolate needs tempering

Obtaining of good tempering :

 Good gloss, and absence of spots.

 Cracking, crunchiness

 Sufficient contraction for good de-moulding.

 Less finger sensitive.

 Resistant to fat bloom for a long time.

Chocolate, Compound Process

 Industrial tempering Disc-type
Sollich Turbotemper

Tempering machines :

 Aasted SuperNova AMC.

*Aasted Mikroverk merged with
A. E. Nielsen.

 Sollich Turbotemper.

 Carle Montanari BETA temperer.

 Buhler Seedmaster

Archimedean
screw-type
Buhler Seedmaster

Chocolate, Compound Process

 Chocolate – moulding & cooling

Entry Middle Exit

section section section

Moderate temperature Low temperature to Moderate temperature to

for chocolate to avoid remove latent heat. prevent condensation.
unstable crystals To contract chocolate The equilibrium solid fat
and required for should be high enough for
Radiation
demoulding. the coating to be dry and
for packing.
Air flow Convection

Cooling belt
Conduction Chocolate, Compound Process
 Right cooling is equally important

Too fast cooling Too slow cooling

Loss of gloss Loss of gloss
Finger sensitivity Loss of shrinking power
White spots Grey spots, rough crystals
Condensation (sugar bloom)
Risk of blooming

Polymorphic system
Entry Middle Exit
section section section
15 oC 8 – 10 oC 15 oC

Chocolate, Compound Process

 Chocolate – storage

 Consistent storage temperature ~ 20 oC

 Low relative humidity < 70%.
 Clean, dry and odorless environment.
 Chocolate can attracts vermin.

Chocolate, Compound Process

 Vegetable fat in chocolate

Product
Requirement A B C D E

1. Raw materials

2. Miscible &
Compatible

3. Rich in .
symmetrical TG

4. Non Lauric

Remark
1. Vegetable fats of the following origin : illipe, palm oil, sal, shea, kokum, mango kernel.
2. Compatible in physical properties for ie melting point, crystallization temperature, melting rate.
3. Rich in POP, POSt, StOSt.
4. Non lauric, and only by process of refining, and fractionation.

Chocolate, Compound Process

 Use of cocoa butter equivalent
in chocolate
100

2 90
80

Percentage of solid fat

80 77
70 10°C

1 70 68
60 15°C
20°C
50

Percentage of solid fat

25°C
60 40
30°C
48 30
50 35°C
20
40 10
0
30 0 10 20 30 40 50 60 70 80 90 100
Percentage of CBE Chocomate
20 to CB

10
2

0
0
32
20 25 30 35 40
3 31
30

Temperature, oC
Temperature, ºC 29 28

Cocoa Butter CBE Chocomate 28

27 CBE Chocomate
26
25 Cocoa butter
24
1 Solid fat content, SFC curve 23 23 Tmin = 23 oC
22
21
Tmax = 28 oC
2 Binary / Compatibility chart 20
tmin = 41 min
0 10 20 30 40 50 60 70 80 90
tmax = 61 min
3 Jensen Cooling Curve Time, mins
Chocolate, Compound Process
 Chocolate lesgislation

Countries Authorisation of vegetable fats in chocolate

Australia Yes, max 5%
Canada No
China Yes, max 5%
EU Yes, max 5%
Gulf States Yes, max 5%
India No
Japan Yes, > 5%, including semi chocolates
Malaysia Yes, max 5%
Mexico Yes, max 5%
New Zealand Yes, max 5%
Russia Yes, > 5%, including supercoatings
Singapore Yes, max 5%
South Africa Yes, > 5%
South Korea Yes, > 5%
USA No

Chocolate, Compound Process

 Chocolate recipe & legislation
Ingredients % DCS DFFCS DMS MF CB Veg DCS DFFCS CB Veg
min min min max
35 14 18 5
Sugar 48,0 0 0 0 0 0 0 0,0 0,0 0,0 0,0
Cocoa mass
Cocoa butter
40,0
7,0
98,5
100
44
0
0
0
0
0
54
100
0
0
39,4
7,0
17,6
0,0
21,6
7,0
0,0
0,0
Dark
Whole milk powder 0 0,0 96 26 0 0 0,0 0,0 0,0 0,0
Cocoa butter equivalent 5,0 0 0 0 0 0 100 0,0 0,0 0,0 5,0
Total 100,0 46,4 17,6 28,6 5,0

Ingredients % DCS DFFCS DMS MF CB Veg DCS DFFCS DMS MF Veg

min min min min max
25 2,5 14 3,5 5
Sugar
Cocoa mass
44,0 0
12,0 98,5
0
44
0
0
0
0
0
54
0
0
0,0
11,8
0,0
5,3
0,0
0,0
0,0
0,0
0,0
0,0 Milk
Cocoa butter 19,0 100 0 0 0 100 0 19,0 0,0 0,0 0,0 0,0
Whole milk powder 20,0 0 0,0 96 26 0 0 0,0 0,0 19,2 5,2 0,0
Cocoa butter equivalent 5,0 0 0 0 0 0 100 0,0 0,0 0,0 0,0 5,0
Total 100,0 30,8 5,3 19,2 5,2 5,0

Ingredients % DCS DFFCS DMS MF CB Veg CB DMS MF Veg

min min min max
20 14 3,5 5
Sugar 44,0 0 0 0 0 0 0 0,0 0,0 0,0 0,0
Cocoa mass
Cocoa butter 28,0
98,5
100
44
0
0
0
0
0
54
100
0
0
0,0
28,0
0,0
0,0
0,0
0,0
0,0
0,0
White
Whole milk powder 23,0 0 0,0 96 26 0 0 0,0 22,1 6,0 0,0
Cocoa butter equivalent 5,0 0 0 0 0 0 100 0,0 0,0 0,0 5,0
Total 100,0 28,0 22,1 6,0 5,0

Chocolate, Compound Process

 History of compound coating

VEGETABLE FATS

NON LAURIC LAURIC

COATING COATING

COCOA BUTTER COCOA BUTTER COCOA BUTTER

EQUIVALENT REPLACER SUBSTITUTE

 Origin : palm, exo fats.  Origin : palm, rapeseed,  Origin : palm kernel,
 Non hydrogenated. soyabean.  Hydrogenated.
 Tempering fat.  Hydrogenated.  Non tempering fat.
 Fully compatible to  Contain trans.  Max 5% cocoa butter
cocoa butter.  Non tempering fat. & milkfat tolerance.
 Excellent meltdown,  Max 20% cocoa butter  Excellent meltdown,
flavour impact. & milkfat tolerance. flavour impact.
 Good meltdown,
flavour impact.
Chocolate, Compound Process
 Compound ingredients

Dark Milk White

 Vegetable fat  Vegetable fat  Vegetable fat
 Cocoa solids  Cocoa solids  Cocoa solids
Cocoa butter Cocoa butter Cocoa butter
+/- Cocoa Mass +/- Cocoa Mass
+ Cocoa Powder
 Sugar
+ Cocoa Powder
 Sugar  Sugar  Milk solids
+ Milk fat
 Milk solids  Milk solids + Whole milk powder
+/- Whole milk + Whole milk powder + Skimmed milk
powder + Skimmed milk powder
+/- Skimmed milk powder + Whey powder
powder + Whey powder + Lactose
+ Lactose
+ Emulsifiers
+ Vanillin, flavours Chocolate, Compound Process
 Vegetable fats in compound coating

100
90

Percentage of solid fat

80 77

70 68
Cocoa Butter
60
50 48 CBE
40 CBR
30
CBS
20
10 2
0
0
20 25 30 35 40
Temperature, ºC

Chocolate, Compound Process

 Vegetable fats in compound coating
- measure of compatibility

CCB/CBE Stabilised 26°C CCB/CBR Stabilized 26°C CCB/CBS Stabilised 26°C

100 100
100 S26N20
90 S26N20
90 S26N25
90

% Soild Fat Content

S26N25

% Solid Fat Content

% Solid Fat Content

80 80 S26N30
80 S26N30
S26N35
70 70
70 S26N35
60 60
60
50 50
50
40 40
40
S26N20 30
30
30 S26N25
20 20
20 S26N30
10 10
10 S26N35
0 0
0
0 10 20 30 40 50 60 70 80 90 100 0 10 20 30 40 50 60 70 80 90 100
0 10 20 30 40 50 60 70 80 90 100
% CBR % CBS
% CBE

Chocolate, Compound Process

 Supercoating recipes using CBE
Dark Milk Dark Milk
100% CBE 100% CBE
Sugar 48 44 48 44
Cocoa mass 40 12
Cocoa butter
Whole milk powder 20 20
Fat-reduced cocoa powder 20 6

CBE Chocomate 3100 12 24 32 30

100 100 100 100
Emulsifier : lecithin + + + +
Emulsifier : PGPR +/ – +/ – +/ – +/ –
Vanillin + + + +
Fat content, % 34 36 34 36

Chocolate, Compound Process

 Compound coating recipes
using CBR

Dark Milk White

Sugar 50 48 46
Cocoa mass 7 8
Whole milk powder 6 20
Skimmed milk powder 10 5
Fat-reduced cocoa powder 16.5

CBR Hisofat 300M 26.5 28 29

100 100 100
Emulsifier : lecithin + + +
Emulsifier : PGPR +/ – +/ – +/ –
Vanillin + + +

Total fat, % (calculated) 32 34 34

Chocolate, Compound Process

 Calculation of compatibility in milk
compound coating using CBR
Milk % CB % milkfat % veg fat
Sugar 48
Cocoa mass (54%) 8 4.3
Whole milk powder (26%) 6 1.6
Skimmed milk powder (1%) 10 0.1
Fat-reduced cocoa powder

CBR Hisofat 300M 28 28

Total 100 4.3 1.7 28

Fat content, % 4.3 + 1.7 + 2.8 = 34

% cb + milkfat in fatphase (4.3 + 1.7) x 100 = 17.6 < 20%
34

Chocolate, Compound Process

 Compound coating recipes
using CBS
Dark Milk White
Sugar 48 44 42
Fat-reduced cocoa powder 15 8
Skimmed milk powder 5 15 22

Isfat H2100EM 32 33 36
100 100 100
Emulsifier : lecithin + + +
Emulsifier : PGPR +/ – +/ – +/ –
Vanillin + + +

Total fat, % (calculated) 34 34 36

Chocolate, Compound Process

 Calculation of compatibility in milk
compound coating using CBS
Milk % CB % milkfat % veg fat
Sugar 44
Fat-reduced cocoa powder 8 0.9
(11%)
Skimmed milk powder (1%) 15 0.2

Isfat H2100EM 33 33
Total 100 0.9 0.2 33

Fat content, % 0.9 + 0.2 + 33 = 34.1

% cb + milkfat in fatphase (0.9 + 0.2) x 100 = 3.2 < 5%

34.1

Chocolate, Compound Process

 Making compound coating
VEGE FAT
VEGE FAT EMULSIFIER
SUGAR

COCOA
GRINDING
MASS MIXING CONCHING
COCOA
REFINING
POWDER
MILK when % cocoa
POWDER mass is low,
VANILLIN REWORK can be replaced
by one-step ball LIQUID
mill process CHOCOLATE
(total fat > 30%)

SOLID
COOLING MOULDING TEMPERING
CHOCOLATE
only if using CBE

STORAGE
Chocolate, Compound Process
Making compound coating
- mixing, refining and fineness

Fine grinding of compound coating

using ball mill refiner.

 Mix all (most) ingredients in the mixer.

 If two roll refining step is required,
recommended mixer fat < 28%.
 If refined sugar (via hammer mill) is
used, recommended mixer fat < 33%.
 Suitable for compound recipe with low
or without use of cocoa mass.
Hence, conching step is not required.
 Grinding media for optimum refining
: 5 – 6 mm steel balls.
 Recipe fat content > 32%.
 Low energy consumption, and
minimal manpower required.
 Grinding to as fine as 20 micron.

Chocolate, Compound Process

Making compound coating –
conching
Conching

 Applicable for recipe < 32% fat

(for ie recipes for inclusion).

 Conche temperature approx. 65 oC .

 In cases where conching can improve

flow properties and moisture content
of compound coating.

 Recipes containing CBE, CBR where

may contain some percentage of CM.

Chocolate, Compound Process

 Compound – moulding & cooling

Entry Middle Exit

CBE section section section
supercoatings
15 oC 8 – 10 oC 15 oC

Entry Middle Exit

Non lauric section section section
CBR coatings
10 – 12 oC 8 – 10 oC 15 oC

Entry Middle Exit

Lauric section section section
CBS coatings 6 – 8 oC 6 – 8 oC 15 oC

Chocolate, Compound Process

 Compound recipe & legislation

Chocolate with cocoa butter alternative (China) SB/T 10402

Dark Milk White
DFFCS ≥ 12 ≥ 4.5
DMS ≥ 12 ≥ 14

Semi chocolate definition (Japan)

Dark Milk White
DCS ≥ 15 ≥7
CB ≥3 ≥3 ≥ 10
DMS ≥ 12.5 ≥ 12.5
MF ≥2 ≥2
Total fat ≥ 18 ≥ 18 ≥ 18

Chocolate, Compound Process

 Flow properties

Factors affecting flow properties;

 Temperature of chocolate/compound coating.

 Percentage of fat content in recipe.

 Particle size of chocolate.

 Presence of emulsifiers for ie lecithin, PGPR.

 Moisture content (< 1.5%) in product.

Chocolate, Compound Process

 Why do we need to control
rheology ?
 To produce perfect shaped and
nice looking products.
 To avoid problems related
incorrect rheology.
 Batch to batch consistency
(for quality control).
 Applications where rheology
control is important;
a. Enrobing
b. Shell moulding
c. Hollow figure moulding
d. Spinning
e. Panning
f. Ice cream dipping
Chocolate, Compound Process
 Sugar free compound coating

Dark Milk
Maltitol – Maltisorb P200a 48 48
Fat-reduced cocoa powder 20 8
Sodium caseinate 10
Isfat H2100EM 32 34
100 100
Emulsifier : lecithin + +
Emulsifier : PGPR +/ – +/ –
Vanillin + +
Fat content, % 34 35

Remark : a. may also use whey protein isolate

(Provon 190)

Chocolate, Compound Process

Flavoured compound coating

White
Sugar 47
Demineralised whey powder 13
Lactose 6
Isfat H2100EM 34
100
Emulsifier : lecithin +
Emulsifier : PGPR +/ –
Flavour +
Colour +/ –
Fat content, % 34

Chocolate, Compound Process