This Chocolate Lectures related to Chocolate and Confectionay subject,in which chocolate from farm to consume totally describe in a good way...

1. LEGAL DEFINITIONS
• Cocoa butter:
Fat extracted from cocoa beans
FFA should not be more than 1.75%
Unsaponifiable matter should not be more than
0.5%. E.g alcohol, tocopherols, sterols etc
(those unable to form soap with NaOH.)
1

2. COCOA POWDER
• Cocoa beans converted to powder after
cleaning, shelling and roasting.
• Not less than 20% cocoa butter (db)
• Not more than 9% moisture
2

3. Fat Reduced Cocoa/Cocoa powder
Cocoa fat containing less than 20% cocoa fat
(db)
3

4. Powdered Chocolate
• Mixture of sugars and cocoa powder.
• The amount of cocoa powder must not be less
than 32%.
4

5. Drinking Chocolate/Sweetened
Cocoa/Sweetened Cocoa Powder
• Contains not less than 25% cocoa powder.
• If it is made from fat reduced cocoa than it
should be labelled as low fat………
5

6. Chocolate
• Product obtained from cocoa products and
sugar and contains not less than
• 35% Dry total cocoa solids
• 18% cocoa butter
• 14% dry non fat cocoa solids.
6

7. Milk Chocolate
• Product obtained from cocoa products, sugar
and milk solids containing not less than:
• 25% dry cocoa solids
• 14% dry milk solids
• 2.5% dry non fat cocoa solids
• 3.5% milk fat
• 25% total fat (milk and cocoa butter)
7

8. Family milk chocolate
• Ingredients are same as milk chocolate i.e
sugar cocoa products and milk. However,
lower limit for total milk solids, and milk fat is
lesser
• Not less than 3.5% milk fat
• NLT 14% dry milk solids.
• Not less than 20% cocoa butter.
8

9. Filled Chocolate/ Chocolate with
centre.
• It is a filled product outer part of which consist
of either milk chocolate or chocolate or white
chocolate etc.
• It however does not include bakery products,
pastery, edible ice etc.
• E.g. wafer chocolates, chocolate with coconut
filling. Etc.
• However outer portion should make more
than 25% of the product by weight.
9

10. White Chocolate
• Product obtained from cocoa butter, milk,
milk products and sugars which contains not
less than
• 20% cocoa butter
• 14% dry milk solids
• 3.5% milk fat.
10

11. Chocolate a la taza
• Product obtained from cocoa products,
sugars, and flour or starch from wheat, rice or
maize.
• The product must not contain less than
• 35% total dry cocoa solids
• 18% cocoa butter
• 14% non fat cocoa solids i.e same as
“chocolate”
• Not more than 8% flour or starch.
11

12. Pralines
• Single mouth full size.
• Filled chocolate. Chocolate should not be less
than 25% of the total weight of the product.
12

13. Use of Additives
• No colors should be used in cocoa or
chocolate based products.
• Ammonium phosphatides (emlsifier) should
not be more than 10 g/kg
• Aspartame max: 2000 ppm
• Lecithin: quantum satis
• Polyglyerol polyricinoleante (emulsifier) max 5
g/kg.
13

14. Labelling Requirement
Product Name:
• Product name must be according to
composition rules laid down in European
Commission.
14

15. List of Ingredients
• Descending order by weight
• Legal name for ingredients must be used.
• If no name exist then a clearly understood
term must be used.
• Additive must be written category followed by
E-number e.g emulsifier (soya lecithin) E 322.
• Following must be declared as allergen in
product.
15

16. Allergens
• Cereals containing gluten
• Crustaceans
• Eggs
• Fish and products
• Peanuts
• Soybeans
• Milk and milk products
• Nuts
16

17. Allergens
• Nuts
• Celery
• Mustard
• Sesame seeds
• Sulphur dioxide.
• Molluscs
• Lupin
17

18. Quantity of certain ingredients (QUID)
• If a chocolat is labelled as “white chocolate
with almonds” then quantity of almonds must
be stated whether it is 7% or 32% so that
customer could distinguish.
18

19. Net quantity in g or kg.
• Net quantity of product must be given
19

20. Special Storage conditions
• Like keep in a cool place
• Keep in a cool, dry place
20

21. Best before
• The time for which the product must maintain
its quality must be clearly given.
21

22. Name and address of the
manufacturer
• Name and address of manufacturer or brand
name must be given.
22

23. Vegetable fat
• If vegetable fat is added to chocolate than it
must be clearly stated as
• “contains vegetable fat in addition to cocoa
butter”.
• This statement must be written separately
from the list of ingredients, must be written in
large and bold and with the product name
nearby.
23

24. Non-fat/reduced fat cocoa and
powdered chocloate
• Such products must state the fat content.
24

25. Milk Chocolate
• It must properly state minimum milk solids.
25

26. 26

27. COCOA BEANS ; From tree to
factory
27

28. COCOA
• Grown 20 degree north of and south of
equator
• Grows in West Africa, south east asia and
south america.
28

29. 29

30. • Ivory coast or corte de ivory produces around
40% of the world’s total production.
• Four main varieties of cocoa are
• Criollo, Forastero, Trinitario and Nacional.
• Botainical name of cocoa is (Theobroma
cacoa. L.)
30

31. Criollo
• These are white cotyledons.
• Mild, nutty, cocoa flavor.
• This variety is susceptible to diseases and
gives low yield therfore it is now very rare.
31

32. Forastero
• This is the major variety grown now a days.
• Also called Ameolnado ( due to melon shape
of pods)
• It is also suitable for west african small farm
holders.
• It gives higher yield and is resistant to pests
and diseases.
32

33. Trinitario
• Cross of Forastero and criollo.
• And thus is a combintion of forastero and
criollo flavors.
33

34. Nacional
• Only grown in Ecuador.
• It is famous for its “Arriba flavor”
• Unlike forastero varieties which are harsh and
bitter, the bitterness level of nacionals is
almost nill and gives smooth flavor. It gives
smooth and sweeter chocolate compared to
other beans.
• Nacionals are characterized with delicate
cocoa flavor, perfumed floral scent including
dominant jasmine note with nutty afternotes.34

35. Cocoa grows in high rainfall areas
• Requires 70 to 80%
humidity during day and
100% humidity during night.
35

36. Cocoa
• Pods develop from flower.
• Pods are called cherelles.
• Pods fully develop in 4-5 months.
• They are 4 to 14 inch long,
• Wt 200g to 1Kg.
• On ripening pods change color from green or
red to yellow or orange.
36

37. 37

38. 38

39. 39

40. Cocoa
• Harvest occurs between October to
December.
• Pods are opened to release the beans using
the machete with the help of a wooden stick.
• 30 to 45 beans are present in each pod that
are attached to central placenta.
• Beans are oval or almond in shape that is
covered with a sweet mucilagionous pulp.
• Beans are separated by hand and placenta is
removed. 40

41. Cocoa bean
• Each bean consist of two coteyledons which
serve as storage organ plus a small embryo.
• Most of the food stored in cocoa bean consist
of cocoa butter comprising around 50% of the
dry weight of the seed whereas the fresh seed
contains around 65% moisture.
41

42. Immediate Post harvest steps
• Fermentation
• Drying
• Both are carried out usually on farm
• Fermentation produces flavor precursors.
• Drying produces stable, non-perishable
commodity.
42

43. Fermentation
• Fresh beans are first heaped in wooden boxes that
have holes for five days enclosed with banana leaves.
• Mixing is done by some farmers on second or third
day
• Natural yeast and bacteria multiply in pulp and cause
breakdown of sugars and mucilage which drains
away in the form of liquid.
• Unfermented beans are slaty, gray colored rather
than purplish brown fermented beans.
• Unfermented beans taste “astringent” and “bitter”
43

44. Fermentation
• Unfermented beans are often used for
extraction of cocoa butter.
• Unfermented beans may be blended with
fermented beans to develop cocoa products.
• Small farmer use heaps whereas in plantations
wooden boxes are used.
44

45. Fermentation
• Wooden boxes are 1-1.5 m across and 1 m
high.
• Shallow bean depth of around 25-50 cm are
preferred at the start of fermentation to
promote good aeration.
• To ensure proper aeration beans are
transferred from one box to another each day.
45

46. Microbiological aspects of
fermentation
• Beans are naturally innoculated with
microrganisms.
• Pulp that surrounds the bean is ideal medium
for growth of Mos as it contain 10-15% sugars.
• Fermentation causes breakdown of pulp
“death of beans” and allows development of
flavor precursors.
46

47. Stages of fermentation
• Stage 1 (Anaerobic yeasts):
• First 25-36 hours are anaerobic and leads to
product of alcohol from sugars under low
oxygen condition.
• Ph is 4 which is quite acidic.
• Bean death occurs on second day usually due
to production of acetic acid and alcohol.
47

48. 2nd Stage (Lactic acid bacteria)
• LABs are present from start of fermentation
but becomes dominant during 48 to 96 hrs.
• Converts sugars and some organic acids into
lactic acid.
• Lactobacillus plantarum,Lactobacillus
fermentum, Leuconostoc
pseudomesenteroides,Enterococcus
casseliflavus.
48

49. 3rd Stage (Acetic acid bacteria)
• Acetobacter pasteurianus, Acetobacter
senegalensis
• They convert alcohol into acetic acid.
• This step is highly exothermic and increases
temperature to around 50 degrees centigrade.
• They also convert mannitol, lactate and
acetate into CO2 and water.
49

50. 50

51. Cocoa Flavor Precursors
• Flavor precursors develop during
“fermentation and drying”
• There are two imp types of cells within the
cotyledon.
• a) Storage cells b) Pigment cells.
• Storage cells contain proteins and fats.
• Pigment cells contain polyphenols and
methylxanthines (caffeine and theobromine).
51

52. Cocoa flavor precursors
• During fermentation first germination occurs
which leads to uptake of water by storage
cells.
• Due to production of alcohol cell death occurs
leading to membrane rupture as a result of
which enzymes come in contact with their
substrates and formation of flavor precursors
take place.
52

53. Cocoa flavor precursors
• Methylxanthines (cause bitterness) reduce to 30%
after fermentation by diffusing from cotyledons.
• PPO acts on flavanoids.
• Anthocyanins cyanidins and sugar.
• This reaction has a bleaching effect and bleaches
purple color of beans.
• Proteins/peptides plus polyphenolic compounds
complex to give purple coloration.
• Drop in PP levels lead to decline in astringency,
antioxidant effect and color.
53

54. • Sucrose invertase reducing sugars.
• Proteins proteases amino acids and
peptides.
• These aforementioned precursors later on
take part in maillard reaction.
54

55. Drying
• The objective of drying fermented beans is to
reduce the moisture level down to 7 to 8% so
that mould growth could not take place.
• In most of the african countries sun drying
takes place.
• The platforms are made of bamboos, plastic,
or wood. Such surfaces prevent
contamination and allow easy removal in case
of rains
• The are spread in form of trays not exceeding
4 inch thickness.
55

56. Drying
• Sun drying is preferable in those areas where
there is ample of sunligth available.
• In central and south america moving and
stackable platforms with movable roofs are
used.
• In areas where sunlight is not available
artificial methods of drying are used based on
use of wood fire or heat exchangers.
56

57. Disadvantages of artificial drying
a) Acidity is higher as shell becomes too hard
and prevents the escape of volatile organic
acids inside the bean.
b) Smoke finds its way into the bean and thus
affects the taste.
Donot overdry otherwise it will make beans
brittle thus affecting its handling.
c) Winnowing and hand sorting is done after
drying to remove debris and broken beans.
57

58. Shipment of cocoa
• Shipped in sisal (sisal plant fiber) and jute.
• Contains 60-65 kg of dry beans.
• Jute sacks are stakable, donot slip, allow
breathing (removal of moisture) and
biodegradable.
58

59. Moisture migration during
shipment.
• Problem occurs due to migration from hot to cold areas.
• Which leads to condensation of water due to reduce capability of air to
hold moisture.
• This moisture drips on the surface of bags and results in mouldy beans.
• Using proper ventillation, absorband pads and insulating layers on top of
cocoa surface to prevent moisture migration and cooling of cocoa beans.
• Cooled cocoa beans are more liable to pick moisture compared to warm
beans. Their moisture may rise from 7 to 8 % to 20 to 30% which
eventually result in mouldy beans.
59

60. Storage of cocoa
• Moisture in cocoa beans should not exceed
8% otherwise mould growth takes place.
• Causes are inadequate drying, moisture pick
up in humid atmospheres and leaking or damp
stores.
60

61. Storage of cocoa
• Place it on wooden pallets above the floor.
• Keep bags away from walls of warehouses.
• Keep each lot of bag segregated and labelled.
• Cocoa is suceptible to tainting therefore keep it away paints,
spices, agrochemicals etc.
• Ventillation should be restored when humidity drops and vice
versa.
• Permanent storage in PE is not recommended.
• Jute sacks allow moisture migration thus helps to come in
equilibrium with RH.
• Diff types of beans require diff humidity levels.
• Storage bays and silos are also used for bulk storage. 61

62. Storage of cocoa
• Ghananian and Brazilian beans require below
75RH to keep moisture below 8%.
• Dominican Republic are hygroscopic and when
stored under 75 RH they may contain 9%
moisture so they are stored at 65 RH. The
beans from this region are actually partially
fermented and thus contain higher amount of
sugars hygroscopic substances thus could
develop mould.
62

63. Storage bays and silos
63

64. Cocoa infestation
• 8% beans are quite stable for years if they are
stored properly.
• Beans are susceptible to moths, beetles and
caterpillars.
• Remedy:
• Fumigation with phosphene (PH3)gas.
• Use of modified atmospheric conditions so
that no pest could survive. No chemical
residues also.
64

65. Cocoa nibs and shell
• Cocoa is composed of two parts shell and
cotyledon.
• Shell is a fiber and is a waste product which is
ground and could be added to made cocoa
fiber rich products.
• Cotyledons are ground to nibs which is the
most valuable part of bean from which cocoa
butter is extracted. The left mass is ground to
cocoa powder.
65

66. Aspects to Judge Cocoa
• Food Safety aspects: Microrganisms, toxins,
heavy metals etc.
• Economic factors: like moisture, cocoa butter
etc.
• Qualitative factors: Like aroma, flavor etc.
66

67. 67

68. Composition of cocoa nib
68

69. Food Safety requirements
69

70. Economic factors
70

71. Qualitative aspects
71

72. FCC= Federation of cocoa commerce, Europe
ICE=Intercontinental exchange
FAO= Food and Agricultural organization, UNO
72

73. Cocoa beans, Sampling & CUT Test.
• Usually one third of the sack are sampled or
alternatively. In a shipment one third from
each sack is colleceted and total is then
quartered before analyzing.
73

74. Classification on the basis of
weight.
• Number of beans in 100 g (3.5oz) or 1 kg (2.2 lb)
• Methods:
• 300 beans will be weighed to get bean weight per 100 g.
• 250 g of beans are weighed and then counted and multiplied
by 4 to give weight/1000 g. (USA).
• Weight 600 g of beans and then count and divide by 6 to get
bean count per 100g. (FCC, Europe)
74

75. Cut test
• Unsatisfactory beans are determined using cut
test on the same sample used for bean count.
• Unsatisfactory includes mouldy bean, slaty
(unfermented bean), flat bean, germinated
bean.
• Bean is cut longitudnally to observe these
defects.
75

76. Mouldy beans
• Clearly visible and give off, flavor
• 2% of mouldy beans could end up in mouldy
flavor in chocolate.
76

77. Unfermented beans
• They appear gray in colour. And are quite
astringent as the polyphenols are not
removed.
77

78. Infested or germinated beans.
• Residues of insects and holes are signs of
infestation.
• While germinated beans are visible because of
their shoot or the hole which allows entry of
insects.
78

79. Flat beans
• These are beans that failed to develop.
Therefore, does not have fully developed nibs.
• Thus affects yield.
79

80. Cocoa butter hardness.
• Depends on environmental condition,
• Cocoa variety
• Fermentation
• Drying steps
80

81. Cocoa butter hardness
• Hard butters are desirable.
• Low temp during last stages of pod
development gives gives butters that are
softer.
• Brazilians butters are usually harder.
81

82. Chapter no. 3
• Industrial Chocolate manufacture: Processes
and factors influencing quality
82

83. Chocolate
• Chocolates are defined as semi-solid suspension made from
cocoa, sugar (optional milk solids, flour) etc having 70%
continuous fat phase.
• It is solid b/w 20-25°C but melts in mouth at a temperature of
37°C.
• It contains triglycerides dominant in Saturated stearic acid
(34%), palmitic acid (27%), monounsaturated oleic acid (34%).
• Source of antioxidants (epicathecin, polyphenols etc)
• Source of minerals like potassium, mg,Cu and iron.
83

84. 84

85. Cocoa processing and technology
• Bean selection and quality criteria
• Degree of fermentation
• Moisture content
• No. of broken beans
• Bean count per 100g
• Degree of mouldiness
• Flavor profile
• Color
• Fat content (minimum 52%)
• Fat quality related to FFA
• Shell content (10-12)%
• Uniformity of bean size and infestation signs 85

86. Cleaning of cocoa beans
• After fermentation and drying cleaning of cocoa nibs is done.
• Beans must be of uniform size to obtain good quality nibs.
• Objectives.
• To remove coarse and fine impurities
• To remove ferrous compounds
• Removal of high density particles and destoning.
• First the beans are passed through large screens tht will remove the coarse impurities, but
beans will pass thru.
• Then the beans are passed through fine screens to remove the fine impurities.
• Counter air flow techniques remove the light weight dust and sand particles.
• Ferrous material is removed through magnets.
• Destoning is done through fluidized bed drying.
86

87. Deshelling
• Apart from legal requirements deshelling
must be done b/c
• Undesirable contaminants in shell. (exposed
part)
• Gives off flavor.
• B/c of hard and fibrous nature it is difficult to
grind.
87

88. Deshelling
• Deshelling must not result in losses of nib and after deshelling must result
in intact nib.
• Methods of deshelling.
• Usual methods include surface drying which makes the shell hard and
thus allows easy removal.
• Infrared drying, fluidized bed drying, air roasters etc.
• Infrared drying forms puff of shell as the beans pass below the infra-red
radiators resulting in removal of moisture from bean shell.
• This causes brittleness in shell facilitating easy removal of shell.
• Another method employs wetting the surface of shell by using steam and
subsequently drying them using a fluidized bed drier.
88

89. Breaking and winnowing
• Beans are broken by a swing-hammer type of
breaker. Centrifugal force is used to break the
beans against impact plate.
• After that air classification is used to remove
shells from the bean.
• Nibs may also be classified into a number of
fractions using air classification.
89

90. 90

91. Sterlization
• Could be done either before or after roasting.
• Done by spraying steam
• Objective is to destroy all pathogenic mos and
reduce the microbial load to 500 per gram
• Mos may come from fermentation, drying
under sun, bagging, etc.
• If sterlization is done after roasting then the
objective is to kill heat resistant bacteria and
spores.
91

92. Alkalization
• Presented by a dutchman Houten and thus named dutch
process.
• The nibs are treated with alkali solution to raise their ph from
5.2-5.6 to 6.8-7.5. Alkali used is sodium or potassium
carbonate (1-2)%.
• Objectives are
• Improve color
• Improve flavor
• Improve dispersibility of cocoa powder in water.
• Neutralize acid content of beans.
• Color develops due to polymerization of polyphenolic
compounds. 92

93. Alkalization
• This could be done before winnowing or after
winnowing.
• If it is done before winnowing then it requires
higher amount of alkali.
• Nib alkalization:
• Nibs are soaked in alkali solution could also be
done in the same drum where roasting is
done. Then it is heated to a 70-80 deg for
color development and then dried.
93

94. Roasting.
• Obj is to develop color and flavor from
precursors produced during fermentation.
• Also removal of moisture down to 2%
• Nibs become friable and darken in color
• Reduces no. of Mos so that food grade cocoa
powder, cocoa butter could be obtained.
• Amino acids and reducing sugar reduce as
they take part in maillard reaction
• Loss of volatile acids .
94

95. Types of roasing.
• 1) Whole bean roasting
• This type of roasting is done before
winnowing. However it results in absorption
of fat by shell due to melting of fat and thus
result in loss of cocoa butter yield. Also during
alkalization more alkali would be required.
95

96. 2) Nib roasting.
• This is done after winnowing and also ease the
alkalization process.
• 3) Liquour roasting.
• Nib is ground to liquor after winnowing and is
then roasting.
• Disadvantage of nib and liquor roasting is that
since deshelling is before roasting therefore
shell may not have hardened thus results in
some amount of shell being adhered to nibs.
96

97. • However this problem is now removed due to
modernized driers.
• Normal roasting temperatures used are 90 to 200
degrees centigrade.
• Low temp 60 min
• Medium temp 40 min
• High temp15 to 25 min
Short roast periods usually give better flavor.
The discharged roasted beans must be cooled rapidly
to prevent overroasting
97

98. How roasting is done??
• Moisture treatment is first done by
condensing the steam over beans which
increase moisture to 15%
• This moisture aids in development of flavor at
40 to 60 degrees during 18 minutes of
processing.
• When at 98-110 a more intense flavor is
produced as moisture reduces to 3%.
98

99. Batch drum roasters.
• Beans or nibs are added to roasters along with
water. The drum which is heated revolves and
beans tumble thus avoidinig localized heating.
• Salmonella and TPC must be tested.
99

100. Shelf roasters
• This type of roaster is divided into a number
of sections.
• Top ones are used for heating while bottom
ones are used for cooling.
• The beans spend a particular retention time in
each shelf and the slides down into another
shelf. The temp in each shelf is controlled with
hot air through special ventillation slots.
100

101. Nib grinding and liquor treatment
• Nibs are ground to liquour.
• Nibs contains cell locked with cocoa butter.
Almost 55% is cocoa butter.
• Butter is released during grinding (30 um) thus
forming cocoa liquour.
• Stone , ball and pin mills
• Grinding is done in stages.
• Cocoa liqour is then heated between 90-100°C
for ageing and microbial destruction.

102. Cocoa Liqour/mass pressing.
• Fat is obtained from cocoa mass/liquour using
hydraulic press employing pressure of
520kg/cm2.
• High fat cake containing 22% and 24% residual fat in
pressed cake.
• Low fat cake containing 10 and 12% residual fat in
pressed cake
• 78-90% of cocoa butter is collected by pressing and
residual fat is removed by supercritical fluid
extraction.

103. Cake grinding (kibbling)
• The pressed cocoa mass is then kibbled or
ground to smaller pieces and is stored based
on its fat cotent and degree of alkalization.
• It may be blended before pulverization to
obtain desired cocoa powder.

104. Cocoa Powder Production
• Kibbles are find into powder using pin mills and
hammer and disc mills.
• Powder is then cooled to crystallize cocoa fat which
prevents discoloration and formation of lumps.
• Storage conditions; (if maintained life for 3 yrs)
a) Temp not greater than 18°C
b) Clean and dry ware houses
c) Humidity not greater than 50%
d) Ware house free from insects,odours, etc.
e) No exposure to sunlight, heat and lamps.

106. Quality parameters for cocoa powder

107. Quality of cocoa powder may vary due
to