1.Chocolate Production Process:
sugar powder, dairy → grease → making sauce → tempering → molding → packaging → refrigeration
In high-end chocolate production, making chocolate sauce and tempering are two key processes.
2.The Chocolate Sauce Usually Has Two Kinds Of Processes:
The first process is: mixing → three rolls of primary grinding → five rolls of fine grinding → refining.
The second process is to put the primary material into the chocolate ball mill machine or chocolate refiner.
The fine grinding and refining are carried out simultaneously. The chocolate ball mill machine or chocolate refiner can be used to finish the fine grinding and refining of chocolate at one time.
After getting the required fineness, various accessories are added. Generally, the first process is used for mass production of chocolate paste: mixing → three rolls, initial grinding → five rolls, refined grinding → refining. For small batches of chocolate sauce, a chocolate ball mill or chocolate refiner is used to refine and refine.
The oil technology in the process flow is generally based on the first process. Chocolate molding generally includes pouring, cooling, stripping, three processes. A chocolate moulding machine must be used when chocolate moulding. The choice of the chocolate moulding machine is very important for chocolate moulding, so it must be carefully selected.
3.Oil Technology In The Process：
(1). Make Chocolate Sauce
When using fat melter to make the chocolate sauce, the total amount of fat in each process must be controlled well. When mixing with a chocolate mixer, the total amount of grease should be controlled at 28%~30%, and all the grease in the total formula should not be added.
Should make the material after mixing to keep a good dry humidity, dry humidity if not controlled well, will have a great impact on the later three rolling initial grindings, five fine rolling grindings.
If the total fat content of the mixture formula is low, it will also affect the fineness of the fine grinding material, resulting in a rough taste. If the total fat content in the mixing formula is high, the operation will be difficult, the working efficiency of the chocolate mixer will be affected, and even the chocolate mixer will be worn down.
When using a chocolate refiner for dry refining, the total amount of oil should be controlled at 30%~32% so that the acid, odor, moisture, and other substances can be fully volatile.
The effect of dry refining can be achieved without the ball of chocolate sauce. At the initial stage of dry refining, the powder temperature in chocolate refiner should be controlled at 45~50°C, so that the heterogeneous dispersion system with oil as the dispersing medium and sugar, cocoa, and milk solids as the dispersing phase can be fully mixed and emulsified to avoid agglomeration, pellets and protein denaturation caused by excessive temperature.
This phase lasts about three hours. At the beginning of the refining process, some phospholipids and cocoa butter can be added to better form an emulsion dispersion. After feeding, the temperature will gradually rise to about 80°C for about two h. In this process, the liquid fat medium extends to form a film layer, which in turn uniformly surrounds sugar, milk solids, and cocoa, forming a highly uniform dispersion system.
This is a key technology for producing chocolate that tastes fine. Maintain the temperature at 80°C for 2 hours to fully volatilize water, sour taste, and a peculiar smell. Then the temperature is lowered, and the remaining grease and phospholipid in the total formula are gradually added to further reduce the viscosity of the material and improve the fluidity of the sauce so as to facilitate the transportation, molding, and pouring of the sauce.
When refining the chocolate refiner, make sure you keep the chocolate refiner stirring at high speed to keep the water content as low as possible.
Tempering In the production of chocolate, the tempering of sauce is a strong process of technology. Generally speaking, industrial chocolate does not need to be tempered by a chocolate tempering machine, while high-grade chocolate must be tempered by chocolate tempering machine.
The purpose is to form stable crystallization and make the sauce have stable viscosity and good fluidity. It is convenient for casting and de-molding on a chocolate moulding machine to give the chocolate a good sheen, prevent whitening, hair parting, and deforming, and extend shelf life.
Temperature regulation process: different types of high-grade chocolate temperature regulation process parameters are not exactly the same.
For example, bitter chocolate is high in cocoa butter. In the first cooling stage, the chocolate tempering machine is used to cool the chocolate sauce from 40~45°C to 34°C. At this stage, the crystallization of cocoa butter begins to form. The second cooling stage requires the chocolate tempering machine to cool the chocolate sauce from 34°C to 29°C. At this stage, the cocoa butter in the chocolate sauce rapidly forms tiny crystalline nuclei.
When the chocolate tempering machine is used for the reheating stage, the temperature of the chocolate sauce rises from 29°C to 30.5°C. The aim is to remove the unstable crystal and obtain a more stable β crystal. The tempering parameters of each kind of chocolate are not completely consistent.
The temperature parameters of the chocolate tempering machine should be set according to the type of chocolate: for example, the tempering parameters of milk chocolate are slightly lower, while the tempering parameters of bitter chocolate are slightly higher.
In actual production, temperature parameters of the chocolate tempering machine can be adjusted according to the results measured by the curve meter of the chocolate tempering machine.
The purpose of setting temperature parameters is to obtain the crystal type of cocoa butter with high crystallization temperature during temperature regulation. Make the finished product more stable, more closely organized, better luster, more delicate taste.
A chocolate moulding machine should be used to mould chocolate moulding immediately after proper tempering by the chocolate tempering machine.
During the moulding process of the chocolate moulding machine, the temperature should be kept constant to avoid large fluctuations in temperature that could damage the correct crystal of cocoa butter. In the cooling molding process, the temperature should not be too low.
Generally speaking, the cooling temperature of the front section of the cold air tunnel should be controlled at about 59°C, and the cooling temperature of the back section of the cold air tunnel should be controlled at about 15°C, so as to avoid condensation of the finished chocolate products caused by the low discharge temperature. At the same time, we should also try to control the migration of grease, prevent chocolate from oil frost.
In fact, due to the complexity of the characteristics of various oils, in production practice, before mass production feeding, we should use fat melter, chocolate tempering machine, Chocolate ball mill machine, and other instruments in the laboratory for experiments.
Production managers should be very aware of the characteristics of the oils used in order to ensure that the wrong oils are not selected and used to avoid economic losses to the company.