Becketts Industrial Chocolate Manufacture and Use

Since the publication of the first edition of Industrial Chocolate Manufacture and Use in 1988, it has become the leading technical book for the industry.

Fully revised, this fifth edition provides up to date information on all major aspects of chocolate manufacture and use, and features new chapters on artisan chocolate making, chocolate compounds and coatings, and sensory evaluation and analysis.

From the beginning it was recognised that the complexity of the chocolate industry means that no single person can be an expert in every aspect of it. For example, the academic view of a process such as crystallisation can be very different from that of a tempering machine operator. It is also known that the biggest selling chocolate, in say the USA, tastes very different from that in the UK. With both of these issues in mind, many topics are covered in multiple chapters by an international group of leading authors, providing different perspectives.

Beckett′s Industrial Chocolate Manufacture and Use is an essential purchase for all those involved in the manufacture, use and sale of chocolate containing products. It is an indispensible handbook for chocolate scientists, engineers and technologists working both in industry and academia.

Notes on Contributors

Preface

1 TRADITIONAL CHOCOLATE MAKING
S.T. Beckett

1.1 History

1.2 Outline of Process

1.3 Concept of the book

2 COCOA BEANS: FROM TREE TO FACTORY
M.S. Fowler & F Coutel

2.1 Introduction

2.2 Growing cocoa

2.3 Fermentation & drying

2.4 The cocoa supply chain

2.5 The cocoa value chain: long–term perspectives and challenges

2.6 Quality assessment of cocoa

2.7 Types and origins of cocoa beans used in chocolate

Conclusions

References

Abbreviations / Acronyms / Organisations

3 PRODUCTION OF COCOA MASS, COCOA BUTTER AND COCOA POWDER
H.J. Kamphuis, revised by M.S. Fowler

3.1 Introduction

3.2 Cleaning of cocoa beans

3.3 Removal of shell

3.4 Breaking and winnowing

3.5 Alkalization

3.6 Bean and nib roasting

3.7 Cocoa mass (cocoa liquor)

3.8 Cocoa butter

3.9 Cocoa press cake and cocoa powder

3.10 Summary

References & further reading

Manufacturers of cocoa processing equipment

4 SUGAR AND BULK SWEETENERS
Ch. Krüger

4.1 Introduction

4.2 The production of sugar

4.3 Sugar qualities

4.4 The storage of sugar

4.5 Sugar grinding and the prevention of dust explosions

4.6 Amorphous sugar

4.7 Other sugars and bulk sweeteners

4.8 Physiological characteristics of sugars, bulk sweeteners and special polysaccharides

4.9 The sweetening power of sugars and bulk sweeteners

4.10 Other sensory properties of sugars and bulk sweeteners

4.11 Solubilities and melting points of sugars and bulk sweeteners

4.12 Maximum conching temperatures of chocolate masses with different bulk sweeteners

4.13 Separate conching process for no sugar added chocolates

4.14 Pre– and probiotic chocolates

Conclusions

References

5 INGREDIENTS FROM MILK
U.P. Skytte and K.E. Kaylegian

5.1 Introduction

5.2 Milk components

5.3 Milk based ingredients for chocolate

5.4 Summary

References

6 CHOCOLATE CRUMB
M.A. Wells

6.1 Introduction and history

6.2 Benefits of milk crumb

6.3 Typical crumb recipes

6.4 Flavour development in chocolate crumb

6.5 Sugar crystallisation during crumb manufacture

6.6 The structure of chocolate crumb

6.7 Typical crumb processes and equipment

6.8 Effect of the crumb process upon the crumb properties

6.9 Changes to crumb during storage

Conclusions

References

7 PROPERTIES OF COCOA BUTTER AND VEGETABLE FATS
G. Talbot

7.1 Introduction

7.2 Cocoa butter

7.3 Cocoa butter equivalents (CBEs)

7.4 Lauric cocoa butter substitutes (CBSs)

7.5 Non–lauric cocoa butter replacers (CBRs)

7.6 Vegetable fats with specific properties

Summary

References

8 FLAVOUR DEVELOPMENT IN COCOA AND CHOCOLATE
G. Ziegleder

8.1 Introduction

8.2 Fermentation

8.3 Drying

8.4 Roasting

8.5 Conching

8.6 Dark chocolate and milk chocolate

8.7 Flavour release in chocolate

References

9 PARTICLE SIZE REDUCTION
G.R. Ziegler & R. Hogg

9.1 Introduction

9.2 Principles of fine grinding

9.3 Grinding equipment

9.4 Cocoa nib grinding

9.5 Chocolate refining

9.6 Particle size reduction and chocolate flow properties

9.7 Particle size and sensory properties

Conclusions

References

10 CONCHING
S.T. Beckett, K. Paggios and I. Roberts

10.1 Introduction: the reason for conching

10.2 The principles of conching

10.3 The three phases of conching

10.4 Conching machines

Summary

References

11. CHOCOLATE FLOW PROPERTIES
B Wolf

11.1. Introduction

11.2. Non–Newtonian flow

11.3. Presentation of viscosity measurements

11.4. Single point flow measurement

11.5. Rotational viscometers

11.6. Vibrational viscometers

11.7. Oscillatory rheometers

11.8. Sample preparation and measurement procedures

11.9. Factors affecting the flow properties of chocolate

11.10. Advanced methods to characterise chocolate flow behaviour

Acknowledgements

References

12 BULK CHOCOLATE HANDLING
J.H. Walker

12.1 Introduction

12.2 Viscosity and viscometry

12.3 Pump sizes

12.4 General criteria for choosing a pump

12.5 Types of pump

12.6 Pipeline pigging

12.7 Storage of liquid chocolate

12.8 Jacketed pipe work

12.9 Valves

12.10 Contamination removal

Acknowledgements

Conclusions

13 TEMPERING
E.Windhab

13.1 Introduction

13.2 Physics of cocoa butter crystallization

13.3 Chocolate tempering technology

13.4 Measurement of temper and its related characteristics

13.5 Tempering process

13.6 Types of tempering machine

13.7 Properties of cocoa butter crystal suspension (CBCS) tempered chocolate

13.8 Other methods of tempering

Conclusions

Acknowledgements

References

Further reading

Machinery manufacturers

14 MOULDING, ENROBING AND COOLING CHOCOLATE PRODUCTS
M.P. Gray, revised and updated by Á. Máñez–Cortell

14.1 Introduction

14.2 Moulding

14.3 Enrobing

Conclusions

Acknowledgements

References and further reading

15 NON–CONVENTIONAL MACHINES AND PROCESSES
D.J. Peters

15.1 Introduction

15.2 Ultrasound

15.3 High shear / low temperature crystallizer

15.4 High pressure temperer

15.5 Extrusion

15.6 Single shot depositors

15.7 Aeration of chocolate

15.8 Cold forming technologies

15.9 Paste conching

Conclusions

References

16 CHOCOLATE PANNING
M. Aebi revised by M.S. Fowler

16.1 Introduction

16.2 Panning methods

16.3 The process of chocolate panning

16.4 Packaging and storage

16.5 The panning department

16.6 Conclusions & future developments

References and further reading

Manufacturers of panning equipment

17 CHOCOLATE REWORK
E. Minson and R. Hofberger

17.1 Introduction

17.2 Rework

17.3 Constraints

17.4 Economics

Conclusions

References

18 ARTISAN CHOCOLATE MAKING
S. Jewett

18.1 Introduction

18.2 Chocolate trends in mature markets

18.3 Selecting the right product lines to make

18.4 Critical considerations

18.5 Taking products to market

18.6 Selecting the right chocolate

18.7 Hand tempering techniques

Conclusions

Additional reading

19 CHOCOLATE COMPOUNDS AND COATINGS
S. Dale

19.1 Introduction

19.2 What are chocolate compounds and coatings?

19.3 Manufacture of compounds and coatings

19.4 How compounds are used

19.5 Benefits of using chocolate compounds

19.6 Trans fatty acids in chocolate compounds

19.7 Environmental aspects

19.8 Summary of the properties of compound coatings

19.9 The future of compound coatings

References and further reading

20 RECIPES
E.G. Wohlmuth

20.1 Chocolate tastes in different countries

20.2 The basic ingredients

20.3 Conching to develop flavours

20.4 Chocolate recipes

Conclusions

21 SENSORY EVALUATION OF COCOA AND CHOCOLATE PRODUCTS
M.L Harwood and J.E. Hayes

21.1 Introduction

21.2 Types of sensory tests

21.3 Special considerations

21.4 General considerations / good sensory tasting practices

Conclusions

References

22 NUTRITIONAL AND HEALTH ASPECTS OF CHOCOLATE
J. Lambert

22.1 Introduction

22.2 Macronutrients

22.3 Vitamins and minerals

22.4 Flavanols and proanthocyanidins

22.5 Methylxanthines

22.6 Cardiovascular disease

22.7 Obesity and metabolic system

22.8 Inflammation

22.9 Neuroprotective and cognitive effects

Conclusions

References

23 QUALITY CONTROL AND SHELF LIFE
M.B. Stauffer

23.1 Introduction

23.2 Finding the perfect bean

23.3 Cocoa bean preparation on arrival

23.4 Cocoa bean cleaning

23.5 Roasting of cocoa beans

23.6 Cocoa nib grinding

23.7 Cocoa butter pressing

23.8 Cocoa powder

23.9 Chocolate manufacturing

23.10 Specifications

23.11 Tempering

23.12 Shelf life of finished confections

24 INSTRUMENTATION
U. Loeser

24.1 Introduction

24.2 Production measurement technology in / on–line, off–line

24.3 Laboratory analysis

24.4 Summary of important analytical procedures in a typical quality assurance laboratory

Conclusions

Acknowledgements

References

25 FOOD SAFETY IN CHOCOLATE MANUFACTURE AND PROCESSING
F. Burndred and L. Peace

25.1 Introduction

25.2 The importance of food safety management in chocolate processing

25.3 HACCP and pre–requisite programmes

25.4 Physical hazards

25.5 Chemical hazards

25.6 Microbiological hazards

25.7 Allergen hazards

Conclusions

References

26 PACKAGING
C.E. Jones

26.1 Introduction

26.2 Confectionery types

26.3 Flow–wrap machinery and sealing

26.4 Materials

26.5 Sustainability

26.6 Portion Control

26.7 Quality control and environmental criteria

References and further reading

27 THE GLOBAL CHOCOLATE CONFECTIONERY MARKET
J.M.A. Thomas

27.1 Background

27.2 The Global Chocolate Market

27.3 Industry supply

27.4 Global production and consumption of chocolate

27.5 Reasons for eating confectionery

27.6 The marketing of confectionery

27.7 The regulatory position (Chapter 28)

Conclusions

References

28 LEGAL ASPECTS OF CHOCOLATE MANUFACTURE
R. Wood

28.1. Introduction

28.2. International standards the Codex Alimentarius

28.3. European standards

28.4. United States of America

28.5. Canada

28.6. BRIC markets

28.7. Use of additives

28.8. Labelling

Conclusions

References

29 INTELLECTUAL PROPERTY; PROTECTING PRODUCTS AND PROCESSES
P.J. Couzens

29.1 Introduction

29.2 Patents

29.3 Trade marks

29.4 Designs

29.5 Copyright

29.6 Contracts and agreements

29.7 Trade secrets

29.8 Defensive publications

29.9 Strategy

29.9 Enforcement

29.10 How to find help

30 FUTURE TRENDS
S.T. Beckett

30.1 Past predictions

30.2 Present position

30.3 Possible future trends

References

GLOSSARY

USEFUL PHYSICAL CONSTANTS

INDEX

About the Editors
Stephen T. Beckett, Formerly Nestlé Product Technology Centre, York, UK
Mark S. Fowler, Formerly Nestlé Product Technology Centre, York, UK
Gregory R. Ziegler, Department of Food Science, Penn State University, USA