Chocolate Production (farm to table concept)

1. Chocolate
CHOCOLATE
INDUSTRY
Sayed
Mohammad
Naim
KHALID
2012
-­‐
MARCH

2. Overview
(1) Facts
(2) History of Chocolate
(3) Production of Chocolate
(4) Prejudices and Truth
(5) Chocolate in everyday life
(6) Bibliography

3. Facts
(1) Facts of Consumption
(2) Nutritional Information
(3) Difference between white chocolate and milk
chocolate

4. Facts of Consumption
Chocolate consumption in kilograms per person and country

5. Facts of Consumption

6. Facts
(1) Facts of Consumption
(2) Nutritional Information
(3) Difference between white chocolate and milk
chocolate

7. Nutritional Information
h>p://www.cacaoweb.net/nutriJon.html

8. Cocoa
Bu>er
is
made
of
Triglycerides
TripalmiJn

9. Cocoa
Bu>er
ComposiJon
• PalmiJc
acid
(~25%)
– C16:0
16
carbon
saturated
fa>y
acid
• Stearic
acid
(~35%)
– C18:0
18
carbon
saturated
fa>y
acid
• Oleic
acid
(~35%)
– C18:1
18
carbon
unsaturated
fa>y
acid
– One
cis
double
bond
at
C9
• Primarily
P/StOP/St
and
P/StOO
structures

10. Cocoa
Bu>er
Crystals
Proposed
structures

11. Melts
in
Your
Mouth
(Not
in
Your
Hand)
Chocolate
Matrix
is
Crystalline
Fat
(Cocoa
Bu>er)

12. Facts
(1) Facts of Consumption
(2) Nutritional Information
(3) Difference between white
chocolate and milk chocolate

13. Difference between
white and milk chocolate
White chocolate Milk chocolate
• Two kinds of white • by definition: less than
chocolate 30% chocolate
 not chocolate. • Milk-chocolate-candy:
• "Real" white chocolate = primarily sugar + spices
candy bark with almost no chocolate
• Allergic to cocoa  contains • Milk chocolate
no cocoa. 12 cocoa beans
• Ingrediens (primarily): cocoa • “Real” chocolate
butter, sugar, milk and 99 cocoa beans
vanilla, without any cocoa
flavoring
Strictly speaking:
chocolate is any product based 99% on cocoa solid and/or cacao fat

14. Some
brands
in
big
consumers
Belgium
Germany
France
Switzerland
Austria
Great
Britain
The
Netherlands
Italy
America

15. Belgium
• Renowned
for
their
rich
chocolate
tradiJons,
Belgium
commands
the
market
in
high
quality
chocolates.
Godiva
Nirvana
Charlemagne
Kim’s
Chocolates
LTD

16. The
Netherlands
• The
Netherlands
hold
such
tradiJons
in
chocolate
manufacturing
that
currently,
all
cocoa
and
chocolate
products
are
processed
in
the
Netherlands
and
exported
to
all
other
countries.
This
is
largely
due
to
the
cocoa
press
invented
by
Coenraad
Van
Houten
Van
Houten
Bensdorp
Droste

17. Germany
• Germany
ranks
as
one
of
the
largest
consumers
of
chocolate
in
Europe.
Leysieffer
Feodora
Hachez
Stollwerck

18. Austria
• Austria
is
more
renowned
for
their
paJsserie
than
their
chocolates.
The
Vienna
torte
is
just
one
example
of
the
experJse.
Mirabell
Heindl

19. Italy
• Italians
prefer
chocolates
that
are
sweet
or
nu>y
in
flavor.
Italian
chocolaJers
are
masters
in
packaging
and
presentaJon.
Caffarel
La
Provenzale

20. Switzerland
• The
Swiss
are
responsible
for
three
of
the
greatest
impacts
on
modern
chocolate
processing.
The
invenJon
of
conching,
by
Rodolphe
Lindt,
combined
with
creamy
fondant
produces
the
smooth
silky
texture
we
enjoy
today.
We
can
also
thank
the
Swiss
for
the
creaJon
of
milk
chocolate.
Lindt/Sprungli
Suchard
Toblerone

21. France
• France
is
unique
from
other
European
countries
in
that
fact
that
they
boast
smaller,
more
independent
chocolate
manufacturers,
each
with
their
own
specialJes.
Bonnat
Valrhona

22. Great
Britain
• Great
Britain
has
undergone
a
transformaJon
since
the
creaJon
of
the
Chocolate
Society
in
1990.
A
resurgence
in
the
consumpJon
of
premium
chocolates
has
replaced
the
tradiJonal
old-­‐style
sweet
milk
chocolate.
Bendick’s
Green
&
Black’s
Cadbury

23. America
• Like
the
BriJsh,
American
prefer
sweet
milk
chocolates.
The
industry
is
dominated
by
a
few
companies,
but
like
England,
the
American
pallets
are
changing
to
premium,
hand-­‐made
chocolates.
Dile>ante
Ghirardelli
Gui>ard
Fran’s
Chocolates
Hershey

24. Overview
(1) Facts
(2) History of Chocolate
(3) Production of Chocolate
(4) Prejudices and Truth
(5) Chocolate in everyday life
(6) Bibliography

25. History of Chocolate
(1) Where does Cocoa come from?
(2) Chocolate in Europe – Some Dates

26. Where does Cocoa come
from?
• First people who made chocolate were the Mayas and
the Aztecs
• They drank chocolate as a bitter and spicy beverage
called “xocoatl” (“bitter water”)
• Chocolate played an important role in their social and
religious life
• It symbolized life and fertility and was also used as
medicine
• It was a drink for wealthy and
important people
(royalty, priests, etc.)
• Cocoa beans were also used
as money

27. History of Chocolate
(1) Where does Cocoa come from?
(2) Chocolate in Europe – Some Dates

28. Chocolate in Europe -
Some Dates
1528: Hernán Cortéz returned to Spain with
cocoa beans and the formula for the
chocolate drink
1615: The Spanish princess Anne of Austria
married Luis XIII of France, so chocolate
came to France
1657: A Frenchman opened the first
“Chocolate House” in London
 became as popular as Coffee Houses

29. Chocolate in Europe -
Some Dates
1674: The first solid chocolate in a stick form had
been sold
End of 17th century: chocolate came to Germany
 first pralines were made by a German cook
 a tax was imposed by Frederick I of Prussia
1792: A chocolate factory was opened in Berlin
1875: The first milk chocolate was put on the
market

30. Overview
(1) Facts
(2) History of Chocolate
(3) Production of Chocolate
(4) Prejudices and Truth
(5) Chocolate in everyday life
(6) Bibliography

31. Cocoa growing countries

32. Cocoa Beans - The Raw
Material

33. Machinery
used
in
chocolate
company
1. Pre-­‐Drying
machine
2. Winnowing
/
Deshelling
machine
3. RoasJng
&
Cooling
machine
4. Grinding
machine
5. TransporJng
such
as
:
1. Screw
Conveyor
2. Bucket
Elevator
3. Fliud
Pump
/
Gear
pump
+
Piping
4. Dumping
StaJon
5. AspiraJon
pipe
to
Cyclone
and
Centrifugal
Blower
6. Plakorm

34. General
producJon
flowchart

35. Flow Diagram of
Chocolate Production
Step 1: cocoa beans

36. HarvesJng
• Harvest
takes
place
twice
a
year
from
November
to
January
and
May
to
July.
• The
fruit
is
hand-­‐picked
to
protect
the
trees.
• Once
harvested
from
the
trees,
the
pods
are
opened
and
their
seeds
are
removed.

37. FermentaJon
• First,
the
beans
and
pulp
are
laid
in
fermentaJon
boxes.
• The
process
of
fermentaJon
produces
heat
requiring
the
beans
to
be
sJrred.
• At
the
end
of
the
5-­‐day
fermentaJon
process,
the
beans
become
brown,
bi>erness
subsides
and
the
flavor
develops.

38. Drying
• Amer
fermentaJon,
the
beans
sJll
contain
too
much
water
to
be
turned
into
chocolate.
• The
beans
are
spread
out
in
the
sunshine
to
dry.
Most
beans
are
sun-­‐dried
for
up
to
14
days.
• Amer
drying,
the
beans
are
inspected
and
separated.

39. Cocoa Beans - Roasting
RoasJng
takes
place
at
210
F
for
10-­‐115
minutes.
RoasJng
sterilizes
the
beans,
enhances
flavor,
and
makes
the
next
step
much
easier.

40. Flow Diagram of
Chocolate Production
Step 1: cocoa beans
Step 2: shell and nibs

41. Winnowing
• Winnowing
is
the
process
of
taking
the
shells
off
of
the
beans.
•
• What
is
lem
over
is
the
“nib,”
the
most
desired
part
of
the
bean.

42. Nibs, Shell and Liquor

43. Flow Diagram of
Chocolate Production
Step 1: cocoa beans
Step 2: shell and nibs
Step 3: cocoa powder

44. Grinding
The
nibs
are
then
ground,
either
by
machine
or
between
two
stones.
A
liquid
mass
called
cocoa
liquor
is
produced.
With
more
grinding
and
the
addiJon
of
sugar,
chocolate
is
made.

45. Flow Diagram of
Chocolate Production
Step 1: cocoa beans
Step 2: shell and
nibs
Step 3: cocoa
powder
Step 4: plain
chocolate

46. Conching
• Conching
is
the
process
of
mixing
the
cocoa
mass
(not
yet
chocolate).
• It
is
conJnuously
mixed
at
a
certain
temperature
to
develop
flavor,
remove
moisture
and
break
down
large
pieces.
This
can
take
hours
to
days,
depending
on
the
desired
outcome.
• The
finest
chocolates
are
conched
for
5
days.

47. Tempering
• The
next
step
is
tempering.
The
chocolate
is
slowly
heated
and
cooled
allowing
the
cocoa
mass
to
solidify
and
stabilize.
• Without
tempering,
the
chocolate
would
separate
and
would
not
harden
well.

48. Crystal
Forms
of
Cocoa
Bu>er
Chocolate
Tempering
Tempered
chocolate
Cocoa
bu>er
is
a
polymorphic
fat
It
can
form
six
different
crystal
structures
with
different
melJng
points
and
properJes

49. Chocolate
Bloom
Tempered
Bloomed
Thermal
abuse
melts
form
V
crystals
Liquid
fat
migrates
to
the
surface
where
it
crystallizes
into
unappeJzing
small,
polymorphic
crystals
of
arbitrary
form

50. Chocolate
+
+



51. Overview
(1) Facts
(2) History of Chocolate
(3) Production of Chocolate
(4) Prejudices and Truth
(5) Chocolate in everyday life
(6) Bibliography

52. Prejudices and Truth
(1) Table of Prejudices and Truth
(2) Advantages of plain, dark chocolate

53. Table of Prejudices and Truth
*
*cheap mass-produced chocolate # plain, dark chocolate

54. Table of Prejudices and Truth
Prejudice Reason Truth
migraine large doses of tyramine only small quantity

55. Table of Prejudices and Truth
Prejudice Reason Truth
migraine large doses of tyramine only small quantity
obesity sugar * a lot of sugar
# less sugar  no
correlation
*cheap, mass-produced chocolate # dark
chocolate (> 70%)

56. Table of Prejudices
and Truth
Prejudice Reason Truth
migraine large doses of tyramine only small quantity
obesity sugar * a lot of sugar
# less sugar  no
correlation
acne no correlation between acne and chocolate proved
*cheap, mass-produced chocolate # dark
chocolate (> 70%)

57. Table of Prejudices and
Truth
Prejudice Reason Truth
migraine large doses of tyramine only small quantity
obesity sugar * a lot of sugar
# less sugar  no
correlation
acne no correlation between acne and chocolate proved
tooth decay Tannin counteracts *lot of tannins
enzyme  caries # calcium and fluoride 
fortification
*cheap, mass-produced chocolate # dark
chocolate (> 70%)

58. Table of Prejudices and
Truth
Prejudice Reason Truth
migraine large doses of tyramine only small quantity
obesity sugar * a lot of sugar
# less sugar  no
correlation
acne no correlation between acne and chocolate proved
tooth decay Tannin counteracts *lot of tannins
enzyme  caries # calcium and fluoride 
fortification
allergy allergy is rare (exception: traces of nuts)
*cheap, mass-produced chocolate # dark
chocolate (> 70%)

59. Table of Prejudices and
Truth
Prejudice Reason Truth
migraine large doses of tyramine only small quantity
obesity sugar * a lot of sugar
# less sugar  no
correlation
acne no correlation between acne and chocolate proved
tooth decay Tannin counteracts *lot of tannins
enzyme  caries # calcium and fluoride 
fortification
allergy allergy is rare (exception: traces of nuts)
addiction no evidence proved (only delight and desire)
*cheap, mass-produced chocolate # dark
chocolate (> 70%)

60. Prejudices and Truth
(1) Table of Prejudices and Truth
(2) Advantages of plain, dark
chocolate

61. Advantages of plain,
dark chocolate
Supports antioxidant effects Prevention of clogged
arteries and heart attacks
Mood enhancer Raises serotonin and
(aphrodisiac) releases endorphins
Rich of magnesium Prevent women of violent
mood, heart disease and
hypertension
Cholesterol free Cholesterol furs up arteries

62. Chocolate in everyday life
(1) Chocolate in media
1.1 advertising
1.2 films
(2) Quotation about Chocolate

63. Chocolate
Fashion
Show
Chocolate
Show
New
York,
November
8,
2005

64. Quotations about
Chocolate
• Chemically speaking, chocolate really is the world’s perfect
food. (Michael Levine, nutrition researcher)
• I have this theory that chocolate slows down the aging
process.
It may not be true, but do I dare take the chance? (unknown)
• I never met a chocolate I didn’t like. (Deanna Troi in “Star
Trek”)
• Simply put … everybody has a price, mine is chocolate!
(unknown)

65. Overview
(1) Facts
(2) History of Chocolate
(3) Production of Chocolate
(4) Prejudices and Truth
(5) Chocolate in everyday life
(6) Bibliography

66. Bibliography
• DELANDRE
FABIEN.
().
FABRICATION
DU
CHOCOLAT.
h>p://vietech2.free.fr/
choco1.pdf
(02,22,2012)
• h>p://www.rainforest-­‐alliance.org/sites/default/files/site-­‐documents/
educaJon/documents/cocoa_slideshow.pdf
(22,02,2012)
• h>p://www.cacaoweb.net/manufacturing-­‐chocolate.html
(22,03,2012)
• h>p://www.cacaoweb.net/nutriJon.html
(22,03,2012)
• h>p://www.li>leford.com/images/08_techinfo/Technifaxes/Food/
10_Chocolate%20Processing-­‐New%20Efficiency%20In%20Chocolate
%20Refining%20and%20Processing.pdf
(01,01,2012)
• h>p://www.allchocolate.com/understanding/how_chocolate_is_made/
at_factory.aspx
(22,03,2012)
• h>p://en.wikipedia.org/wiki/Chocolate