MANUFACTURING PROCESS OF CHOCOLATESGROUP :- 3

MEMBERSGEETHIKA MOHAN y MOHAMMED SAFWAN y SREENATH y MASLOVA y SRUTHI y PONNIy

SHABEEBA SHAMLA JITHEESH NIKHIL VIJESH

CONTENTSy y y y y y y y y y y

INTRODUCTION HARVEST VARIETIES FERMENTATION/ DRYING CLEANING/ ROASTING CRUSHING/ SHELLING BLENDING/ GRINDING COCOA BUTTER/ POWDER CONCHING TYPES OF CHOCOLATES PACKAGING

INTRODUCTIONy y y y y

cocoa-bean - the heart of the sweetest delicacy in the world - is bitter. Turning cacao seeds into chocolate requires time, effort, and artistry. fascinating process that takes you from tropical rainforests to gleaming factories. First, farmers grow cacao, they harvest, ferment, and dry it by hand. traders and import/export houses sell the seeds on the Coffee, Sugar, and Cocoa Exchange to companies that process the seeds into various chocolate products.

PROCESS:PROCESS:y HARVEST. y VARIETIES. y FERMENTATION. y DRYING. y CLEANING. y ROASTING. y CRUSHING.

y SHELLING y BLENDING. y GRINDING. y COCOA BUTTER. y COCOA POWDER. y CONCHING. y PACKING.

COCOA @ CHOCOLATE

Nutrition Facts for Cocoa and ChocolateCocoa and chocolate contain a large amount of antioxidants (flavinoids). Cocoa and dark chocolate may keep high blood pressure down and reduce the blood's ability to clot, thus the risk of stroke and heart attacks may be reduced. The darker chocolate with the most concentrated cocoa will be the most beneficial. According to an Italian study, a small square (20 g) of dark (bittersweet) chocolate every three days is the ideal dose for cardiovascular benefits. The nutrition values presented below are based on review of a selection of brands.

Ingredient Fat

Cocoa - low fat (European type)

Cocoa - high fat (Breakfast cocoAa)

Unsweetened chocolate

Bittersweet chocolate

Semisweet chocolate and baking chocolate

Fat Carbohydrates

10-15% 45-60%

20-25% 45-60%

45-55% 30-35%

33-45% 20-50%

20-35% 50-70%

Sugars Dietary fibers

0-2% 20-35%

0-2% 30-35%

0-2% 15-20%

13-45% 5-8%

45-65% 3-8%

Protein

17-22%

15-20%

10-15%

5-10%

3-8%

Calories per oz

ca 60

ca 90

140-150

150-160

130-160

Calories per 100 g

ca 200

ca 300

470-500

500-550

450-550

THE VARIETIESThere are two quite different basic classifications of cocoas. 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. .The main growing area is West Africa. The cocoa tree can flourish only in the hottest regions of the world.

COCOA @ CHOCOLATES

HARVESTING

COCOA

Cocoa trees grow world wide in the warm and wet belt.

Cocoa is considered to be the food of god Cocoa tree produces its first crop in between 4-5 years Cocoa can be harvested throughout the year its main seasons are November January and May June.

I t is harvested by hand or with the steel rod , the use of machine may cause damages to the tree and flowers. The beans are taken out by cutting the pods crosswise. The whitish beans which are surrounded by milky ,sticky sweet tasting pulp. The pods will be 20cm in length and 500gms in weight. Each tree will produce 20-30 pods per year.

The shell consitutes 75% of the pod weight. The fresh beans to dry beans ratio will be 3:1.

FERMENTATION:FERMENTATION:y y

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The fermentation process is decisive in the production of high quality raw cocoa. The technique varies depending on the growing region; in some places the beans are placed in heaps, in others they are laid out in baskets or large boxes. In the course of the complex fermentation process, the cocoa beans undergoes a number of important changes. The sugar containing fruit pulp, which would otherwise be difficult to dispose of, is broken down by ferments, and the heat thus produced, bringing the mass to a temperature of about 50 0C, destroys the germination properties of the cocoa seeds.

The astringent and bitter taste diminishes, and at the same time, new substances are formed which are precursors of the aroma components and from which the true cocoa aroma later develops during the drying and roasting operations. y During these final stages, the beans of the Criollo variety turn a brownish-yellow colour and those of the Forastero variety become violet-brown.y

DRYING:DRYING:After fermentation, the raw cocoa still contains far too much water; in fact, about 6o%. Most of this has to be removed. y After a week or so, all but a small percentage of the water has evaporated, the beans have taken on a browner colouring and the aroma has become more pronounced. y after having been packed into jute sacks, weighed and classified, it is exported to the great ports of Europe and North America.y

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Next, the roasted beans are winnowed. Winnowing removes the meat (also known as the nib) of the cocoa bean from its shell

CRUSHING & SHELLINGThe roasted beans are now broken into medium sized pieces in the crushing machine.

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It involves breaking down cocoa to fine particles

WINNOWING/SHELLING: y Winnowing means

shelling y After the beans have been roasted and cooled, their shells are thin and brittle. y They move to a machine called the winnower, which cracks open the shells.

y Air blows

away the cracked outer shell and the husk, and sorts the remaining nibs by size. The nib is the heart of the bean (also called the kernel or the meat), from which the chocolate is made. nibs are now ready to be ground into a paste that will eventually become chocolate.

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y The roasted

BLENDING:BLENDING:y

At this stage the chocolate liquor and other ingredients are kneaded together according to the kind and quality of the chocolate being made. Most chocolate is a blend of beans, selected to achieve a specific consistent taste from year to year. secret of every chocolate factory lies in the special mixing ratios which it has developed for different types of cocoa.

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milk chocolate, cocoa butter and chocolate liquor are combined in varying proportions; sugar and full cream milk (generally condensed milk) are added. y Dark chocolate uses the same process but without milk. y White chocolate is made with cocoa butter, milk and sugar and does not contain chocolate liquor. y The ingredients can be churned together for hours; the resulting is dried to form a crumb which is ground with more cocoa butter in the next phase.

GRINDING:GRINDING:y

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There are usually two stages of grinding in the manufacture of fine chocolate. In the first stage, the nibs are ground into a thick paste similar to freshground peanut butter, called the chocolate liquor. it is neither liquid nor contains any alcohol. chocolate liquor is also called cocoa or cacao liquor, chocolate mass, cocoa mass, cocoa solid, cocoa paste or chocolate paste. In the United States Food Standards of Identity, it is known simply as chocolate. Once further refined, it also is called unsweetened baking chocolate.

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The crushed cocoa beans are now pre-ground by special milling equipment and then fed on to rollers where they are ground into a fine paste. This is dark brown in colour with a characteristic, strong odour. During cooling it gradually sets: this is the cocoa paste. For eating chocolate, the appropriate amount of sugar is added except for 100% cacao bars. To avoid a grainy taste in the finished chocolate, another grinding takes place to reduce the particle size.

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PRESSING:PRESSING:If cocoa powder is being made, the chocolate liquor is further processed into press cake or pressed cake, and cocoa butter. y The chocolate liquor or mass is put into hydraulic presses and extremely high pressure, 6000 pounds per square inch, is applied to drain off the clear, golden liquid cocoa butter. y The press cake that is left is cooled, pulverized and sifted into cocoa powder.y

COCOA BUTTER:BUTTER:y 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 POWDER:POWDER:y

After 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. 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.

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CONCHING

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Conching is a process which removes moisture and acidity from the chocolate, eliminates undesirable odors, fully evolves the desirable flavors and aromas and further smoothes the particles

During conching, the cocoa mass is poured into a stirring and milling machine y It is rolled, turned and aired at a temperature of about 180Fy

The rollers can produce different degrees of agitation and aeration in order to develop and modify the chocolate flavors y The temperature, mixing regimes and length of conching vary according to formulas that create different outcomes in the chocolate.y

The process of conching may last for a few hours to three full days, and in the case of coatings, up to six days y The time depends on the bean and the preference of the producer y However, a key differentiator is the age of the conch y Fine chocolate should melt in your mouth without any grainy feeling on the tongue.y

PACKING:PACKING:The finished chocolates solidify in a cooling tunnel. y In a large operation, a conveyor belt transports the chocolates to the packing machines or packing lines y the entire manufacturing process occurs without a human hand touching the chocolates. y it should be stored at a temperature between 54F and 65F. The ideal place that meets these requirements is a refrigerator!y

TYPES OF CHOCOLATES:CHOCOLATES:types of chocolate may be produced with ordinary cacao beans (mass-produced and cheap) or specialty cacao beans (aromatic and expensive) or a mixture of these two types. y The composition of the mixture, origin of cacao beans, the treatment and roasting of beans, and the types and amounts of additives used will significantly affect the flavour and the price of the final chocolate.y

TYPES OF CHOCOLATES:CHOCOLATES:ywhite

chocolate. ymilk chocolate. ysemisweet chocolate. ybittersweet chocolate. yunsweetened chocolate.

WHITE CHOCOLATES:CHOCOLATES:-

MILK CHOCOLATES:CHOCOLATES:-

SEMISEMI-SWEET CHOCOLATES:CHOCOLATES:-

BITTER SWEET CHOCOLATES:CHOCOLATES:-

UNSWEETENED CHOCOLATES:CHOCOLATES:-