109
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

Chocolate lectures

Embed Size (px)

Citation preview

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

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

Fat Reduced Cocoa/Cocoa powder

Cocoa fat containing less than 20% cocoa fat (db)

3

Powdered Chocolate

• Mixture of sugars and cocoa powder.

• The amount of cocoa powder must not be less than 32%.

4

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

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

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

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

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

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

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

Pralines

• Single mouth full size.• Filled chocolate. Chocolate should not be less

than 25% of the total weight of the product.

12

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

Labelling RequirementProduct Name:• Product name must be according to

composition rules laid down in European Commission.

14

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

Allergens

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

16

Allergens

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

17

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

Net quantity in g or kg.

• Net quantity of product must be given

19

Special Storage conditions

• Like keep in a cool place• Keep in a cool, dry place

20

Best before

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

21

Name and address of the manufacturer

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

22

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

Non-fat/reduced fat cocoa and powdered chocloate

• Such products must state the fat content.

24

Milk Chocolate

• It must properly state minimum milk solids.

25

26

COCOA BEANS ; From tree to factory

27

COCOA

• Grown 20 degree north of and south of equator

• Grows in West Africa, south east asia and south america.

28

29

• 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

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

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

Trinitario

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

criollo flavors.

33

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

Cocoa grows in high rainfall areas

• Requires 70 to 80% humidity during day and 100% humidity during night.

35

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

38

39

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

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

Immediate Post harvest steps

• Fermentation• Drying• Both are carried out usually on farm• Fermentation produces flavor precursors.• Drying produces stable, non-perishable

commodity.

42

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

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

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

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

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

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

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

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

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

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

• Sucrose invertase reducing sugars.• Proteins proteases amino acids and

peptides.• These aforementioned precursors later on

take part in maillard reaction.

54

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

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

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

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

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

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

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

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

Storage bays and silos

63

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

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

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

Composition of cocoa nib

68

Food Safety requirements

69

Economic factors

70

Qualitative aspects

71

FCC= Federation of cocoa commerce, EuropeICE=Intercontinental exchange

FAO= Food and Agricultural organization, UNO

72

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

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

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

Mouldy beans

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

flavor in chocolate.

76

Unfermented beans

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

77

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

Flat beans

• These are beans that failed to develop. Therefore, does not have fully developed nibs.

• Thus affects yield.

79

Cocoa butter hardness.

• Depends on environmental condition,• Cocoa variety• Fermentation• Drying steps

80

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

Chapter no. 3

• Industrial Chocolate manufacture: Processes and factors influencing quality

82

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

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

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

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

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

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

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

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

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

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

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

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

• 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

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

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

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

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.

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.

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.

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°Cb) Clean and dry ware housesc) Humidity not greater than 50%d) Ware house free from insects,odours, etc.e) No exposure to sunlight, heat and lamps.

Quality parameters for cocoa powder

Quality of cocoa powder may vary due to