CHOCOLATE PROCESS TECHNOLOGY

Chocolate Process Technology

Introduction
Physical basis of chocolate
Chocolate tempering
Chocolate coating
Chocolate moulding and aerating
Chocolate cooling
Fat blooming
Resume
Literature

Karsten Richter
Process-Engineering
SOLLICH KG
Siemensstraße 17-23
32105 Bad-Salzuflen
Germany

E-Mail: [email protected]

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Table of contents: Sheet:

1. Introduction ...................................................................................................................... 3
2. Physical basis of chocolate .............................................................................................. 3
2.1. Viscosity and yield point ........................................................................................... 4
2.2. Characteristics of cocoa butter ................................................................................. 4
3. Tempering........................................................................................................................ 6
3.1. Typical chocolate process flow schemes .................................................................. 8
3.2. Degree of temper ...................................................................................................... 9
3.3. Measuring the degree of temper ............................................................................... 9
3.3.1. Tempermeter ................................................................................................... 9
3.3.2. Tempergraph ................................................................................................. 11
4. Chocolate coating .......................................................................................................... 13
4.1. Outboard enrober ................................................................................................... 13
4.2. Inboard enrober ...................................................................................................... 16
4.3. Coating equipment.................................................................................................. 17
5. Chocolate moulding and aerating .................................................................................. 17
6. Cooling........................................................................................................................... 18
7. Fat blooming .................................................................................................................. 20
7.1. Fat blooming caused by automatic crystal conversion (incorrect tempering).......... 20
7.2. Fat blooming caused by migration .......................................................................... 20
7.3. Conditions to prevent and/or delay fat blooming ..................................................... 20
8. Resume ......................................................................................................................... 21
9. Literature........................................................................................................................ 21

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1. Introduction

”Chocolate“ .... Pick-me-up, energy source or elixir .....

Since the discovery of the ”brown gold“ in the 16th century the manner in which it is con-
sumed has altered continuously. Initially, cocoa was served as an exotic beverage. Later,
it was blended with honey, then sugar. In the 17th century chocolate was treated as a
medical product, with the first praline chocolates also created around this time.
It was not until the 18th century that the sale of chocolate moved to specialised merchants.
The most famous chocolate manufacturers on the market today were all established in the
19th century. This era, the age of technological invention, also saw chocolate progress to
become an affordable foodstuff.
The most common form in which chocolate is consumed is the bar, which has long since
changed from its original format. The variety on offer is almost limitless. Current fashions
in the world of chocolate are varieties with a particularly high cocoa proportion and exclu-
sive cocoa types from a particular area of cultivation, with fillings and additional sub-
stances also popular. Especially fashionable are chocolates which have seen the addition
of aromas and spices such as cinnamon, ginger, chili, pepper and thyme.
Naturally, pralines and confectionery are also popular, manufactured by small confection-
ers using premium ingredients and encased with fine coatings.
One specialized form is aerated chocolate (gas injection with nitrogen, carbon dioxide or
nitrous oxide).
This chapter describes the chocolate processing between the liquid phase and the wrap-
ping area, explains the basic compositions of chocolate together with its physical proper-
ties, introduces the required processes as tempering, coating, moulding, cooling and finally
provides some practical hints to prevent from fat blooming.

2. Physical basis of chocolate

Three types of chocolate are differentiated:
- Bitter chocolate:
Mixture of sugar, solid cocoa components, cocoa butter, up to 5 % milk fat
- Milk chocolate:
Mixture of sugar, solid cocoa components, cocoa butter and milk fat
- White chocolate:
Mixture of sugar, cocoa butter and milk fat

To obtain warm and liquid chocolate which can be

processed it is necessary for the chocolate to run through
a physical process in order to generate a certain crystal
structure within the cocoa butter. This so-called tempering
process, however, requires knowledge of the characteris-
tic physical properties of the cocoa butter.

Fig. 1

Fig. 1: Seed crystals

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2.1. Viscosity and yield point
Both the viscosity and flowability of the chocolate can be measured. The viscosity is a
measure for the viscidity of a material, characterized here by the resistance occurring
when stirring the chocolate. It is measured according to ”Casson“ at 40 °C (in melted state)
in [Pas]. The obsolete unit is [cPoise], where 1 Pas = 1000 cP. In tempered state, the
chocolate has the 1.5 to 2-fold value as compared with the measuring value. Viscosity is a
decisive factor in terms of processing possibilities, safe course of process and availability
of a machine. It depends on the following:

- Fat content: The higher the fat content the lower the viscosity
- Particle size: The lower the particle size the higher the amount of fat is bound at the
surface at the same viscosity
- Lecithin content: Addition of emulsifier approx. 0.4 % (promotes flowability)
- Tempering level: The higher the tempering level the higher viscosity
- Temperature: The higher the temperature the lower viscosity
- Water content: The higher the water content the higher viscosity
(normal water content of chocolate is approx. 0.8 %,
cooking chocolate approx. 2 %)
Important: Under no circumstances should chocolate be mixed with
water!!!

The yield point, also measured at 40 °C, is the force which – caused at a certain inclination
of a surface – causes the chocolate to flow. Its measure is [Pa]. Flowability is required
specifically when producing hollow products and thin coats. The emulsifier PGPR can par-
ticularly influence the yield point.

2.2. Characteristics of cocoa butter

- Cocoa butter is polymorph:
Cocoa butter can solidify in different forms of crystals, where only the highly melting
forms ßV and ßVI are stable. The ßVI form is a super stable crystal which forms only
after a longer period of storage. A tempering machine can only effect formation of the
crystal form ßV. This crystal form provides good gloss, long shelf life and good moul-
dability).

Fig. 2

Fig. 2: Melting ranges of the different crystal forms

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- Cocoa butter is very inert when forming the first nuclei

Due to these characteristics it must be cooled down below the melting range of the
ßV form when tempering (pre-crystallization). As unstable crystals may also be
formed here, highly developed tempering units are provided with so-called re-heating
zones where the temperature of the chocolate can be increased to the extent that
unstable nuclei melt out. The pre-crystallization level which can be achieved, i.e. the
percentage of solidified fat as compared with the total amount, depends on the time,
temperature and intensity of mixing. Solidification and melting curve do not coincide.

Fig. 3

Fig. 3: Self-heating due to released heat of solidification

- Cocoa butter is monotropic

Monotropic means that the different crystal forms are converted automatically from
low melting to higher melting crystal forms. Due to this crystal conversion in a fi-
nished chocolate product, heat energy is released which may result in fat blooming at
the surface of the product. To exclude fat blooming right from the beginning, stable
crystals only should be formed during the tempering process.

- Cocoa butter is a mixture of different triglycerides

Cocoa butter is, in common with other fats, a triglyceride where three fatty acid mole-
cules form a chemical composition with glycerin.

Fig. 4

Fig. 4: Structure of a triglyceride (stylized)

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As different triglycerides also have different properties, the chocolate may have a
different melting and solidification behavior – despite the same recipe; for example,
if cocoa butter from another country of origin or a different production process is
used. For milk chocolate, the hardness, melting and solidification behavior is influ-
enced additionally by the softer milk fat with a lower melting range

- Seed crystals

Cocoa butter inclines to solidify in form of the seed crystals during final cooling.
However, the rate of growth must be taken into consideration here, i.e. cooling
should not be too abrupt until the beginning of the solidification process.

Fig. 5

Fig. 5: Seed crystals

3. Tempering

Tempering in its conventional form relies on a tempering unit producing seeds of both the
correct crystal form and in the correct quantity to ensure that the bulk of the chocolate
crystallizes in the same form during subsequent cooling. Such a tempering machine is a
highly developed heat exchanger which nowadays is provided with computer aided control
equipment and touch screen operating environment. In the past, screw-type tempering
machines were preferred which could be installed both in horizontal and vertical positions.
All enrobers with installed tempering unit were operated with horizontally arranged units.
Because of increased output requirements, wear at the tempering screws and – last but
not least – limited space conditions, the disk-type tempering machine has particularly es-
tablished its place among the types of machine now on the market. This is because of its
flexibility and excellent heat transfer, i.e. it can be used to give outputs ranging from 200 to
18,000 kg/h. Heat exchanger disks arranged one on top of the other form the tempering
column. Each heat exchanger disk consists of a water chamber and a chocolate chamber.
A mixing disk is operated in each chocolate chamber which is driven by the central shaft.
This machine is used to temper and/or pre-crystallize liquid chocolate prior to processing
in an enrober and/or moulding line. Here, the chocolate is cooled down in a controlled
physical process under simultaneous intensive mixing in the cooling stage such that the
so-called seed crystals are formed. In the re-heating stage, the chocolate is then heated
up again so that unstable crystals melt out. The art of tempering is to form a certain homo-
genous crystal structure of predominantly stable ßV crystals within the cocoa butter.

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The tempering process is a circulation process. On one hand, the chocolate is tempered,
on the other, the chocolate which is not required has to be melted again before being
passed into the tempering machine again. The minimum temperature for a crystal-free
chocolate is 45°C. Tubular heat exchangers are preferably used as de-crystallization units;
these have to be filled with warm water with a temperature between 55°C and 60°C.
Only about 1% of the cocoa butter is crystallized during one pass. This seems to be a very
low percentage seen at the first glance, but these crystals are the important seed crystals
for further crystallization.
The tempering machine is responsible both for a constant degree of tempering, constant
viscosity and the gloss and shelf life of the finished product. It should always be chosen on
the basis of its robustness and availability.

Fig. 6

Fig. 6: Tempering machine

Tempering (pre-crystallization) is required:

- To accelerate solidification of the chocolate to be processed

- To enable solidification in the stable bV crystal form
- To give a good gloss on the surface of the chocolate
- To give sufficient heat resistance for further process-handling
- To avoid fat bloom
- To give good contraction and mouldability
- To give a fine fracture when the chocolate is broken

Important:
Tempering does not mean to cool down to a certain chocolate temperature but to
generate a certain stable crystal structure within the cocoa butter.

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3.1. Typical chocolate process flow schemes

Feeding of an enrober according to the recirculation tempering process

Fig. 7

Feeding of a bar or shell moulding line

Fig. 8

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3.2. Degree of temper

The level of tempering and/or the amount of solidified fat crystals is decisive for evaluating
the quality of the chocolate to be processed. A too low percentage (under-temper) will re-
sult in too long solidification times during final cooling and the consequences may be poor
gloss and a low shelf life. A too high solidification percentage (over-temper) will result in an
increased viscosity of the chocolate to be processed and the consequences may be poor
contraction during final cooling and poor gloss.

3.3. Measuring the degree of temper

Different methods of measuring are known. Most of them measure the temperature curve
of the chocolate while cooling it down and analyze the inflection point. Others are proceed-
ing the opposite way. The DSC method (differential scanning calorimeter) heats up a
chocolate sample with a constant heating rate and measures the quantity as well as the
quality of the prior built crystals (expensive and complicated method). Here below the de-
scription of two popular instruments: Tempermeter and Tempergraph.

3.3.1. Tempermeter
The mobile Tempermeter can be used to determine the degree of temper by simple mea-
suring within approx. 10 min. For measuring, a small amount of tempered chocolate must
be filled in a sample cup. The sample is then cooled down under standardized conditions,
at the same time, the temperature curve is recorded and then a cooling down curve is
printed. The degree of temper is determined automatically by the instrument from the
slope of the temperature curve in the inflection point. Crystallization starts at this point.
Heat of solidification, which is a measure for the degree of temper, is released. It is printed
as numerical value under the designation “temper index”. The temperature at which the
chocolate starts to solidify in the sample cup (temperature in inflection point) is called the
crystallization temperature. It indicates the type of the formed crystals (high or low melting)
and thus the quality of temper.
The Tempermeter requires only a mains connection and works with installed thermo-
electric cooling. Thus the process runs under the same cooling conditions at all times.
If a deviation from ideal tempering is found when measuring the degree of temper,
a correction is possible by a simple change of the setting at the tempering machine. This
ensures working at a nearly constant degree of tempering during the whole period of pro-
duction. Equal viscosity will result in an equal coating thickness, equal product weights,
equal cooling times, equal shell thickness, etc. The visual appearance of the product can
be improved, the rejects can be reduced by monitoring the tempering level and enormous
chocolate savings can be achieved by means of close production tolerances.
Despite any theoretical explanation, the customer should always determine the optimum
degree of temper required by him. The measuring instrument is a help for reproducing all
settings. But even in these applications, the gloss and shelf life of the finished product
should be checked.

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Temper curves for chocolate with normal fat content

Too weakly pre-crystallized

Under-tempered = tempering machine too warm
Degree of temper (temper index) = 3.5
Crystallization temperature (Crystallization) = 21.5°C (de-
pends on chocolate type)
This curve is obtained if a too weakly pre-crystallized choco-
late is tested. The low percentage in nuclei initially allows a
deep drop of the temperature before solidification is started.
Because a relatively high percentage of still liquid fat phase
is present in the under-tempered chocolate, a relatively high
amount of heat is released during solidification, which caus-
es the chocolate to self-heat.
Fig.9

Ideally pre-crystallized
ideally tempered
Degree of temper (temper index) = 5.0
Crystallization temperature (Crystallization) = 22.0°C (de-
pends on chocolate type)
An ideally pre-crystallized chocolate results in this typical
temper curve with the vertical course of curve during the so-
lidification phase. Here, the released heat of solidification
and the heat dissipated by the cooling unit are temporarily in
balance.

Fig.10

Too highly pre-crystallized

Over-tempered = tempering machine too cold
Degree of temper (temper index) = 7.2
Crystallization temperature (Crystallization) = 22.8°C (de-
pends on chocolate type)
This curve is obtained if the chocolate is interspersed with
crystal nuclei. The consequence is that solidification starts at
a relatively early time, i.e. at a relatively high temperature.
Because only a relatively low fat portion in the sample cup
can be caused to solidify due to the high degree of crystalli-
zation, the released heat of solidification is relatively low for
this chocolate. This becomes evident via a flat course of the
Fig.11
cooling down curve in the area of solidification.

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Evaluation criteria of the measuring protocol and temper curve

Geometrical course of the temper curve, in the area of solidification

The experienced user of the instrument will recognize the degree of temper at first glance.
The degree of temper is given as a numerical value with the designation “temper index”.

1 = very highly under-tempered

under-tempered 2 = highly under-tempered
3 = under-tempered

4 = slightly under-tempered
well tempered 5 = ideally tempered
6 = slightly under-tempered

7 = over-tempered
over-tempered 8 = highly over-tempered
9 = very highly over-tempered

Depending on the requirements, it is possible to change the degree of temper at the tem-
pering machine which should be performed in 0.2 – 0.3 °C increments. A good degree of
temper at high crystallization temperature requires a constant chocolate inlet temperature
of at least 45 °C

3.3.2. Tempergraph
The Tempergraph is an automatic measuring instrument which determines online the de-
gree of temper of a pre-crystallized chocolate. The Tempergraph is installed in the dis-
charge piping of a tempering machine.
The sampler takes a chocolate sample from the chocolate piping at regular intervals. This
sample is cooled thermo-electrically and caused to solidify. At the same time, the installed
sensor measures the temperature course. At the end of measuring, the solidified sample is
placed in the heating cylinder, melted and then added to the chocolate flow.
The touch screen PC is responsible to control the sampler, regulate the cooling and heat-
ing temperatures, check all functions and prepare and save the measuring values.
The measurements are started and the results are saved for evaluation at regular inter-
vals. After determine the degree of temper and the temperature of crystallization, the soli-
dification curve is displayed graphically on the screen.
All curves and evaluations are saved continuously and can be called at any time. An USB
port is used to transfer the data to an external data carrier.

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1 2 3 4 5 6

Fig. 12

Fig. 12: Tempergraph

1. Piston with temperature sensor

2. Motor for longitudinal sensor movement
3. Cooling chamber
4. Cooling device
5. Adapter piece
6. Melting chamber
7. Chocolate discharge piping

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4. Chocolate coating:
The basic requirements of a chocolate coating machine also named enrober have not
changed for decades: Products such as bars, chocolate centers or cookies are to be
coated fully or partially with chocolate. Special attention is paid here to high weight accu-
racy and a uniform bubble-free appearance.
After cooling, a shiny and handling-resistant product should be available for packaging.
Processing of real chocolate always requires a tempering unit.
Enrobers are differentiated between outboard (without installed tempering unit) and in-
board enrobers (with installed tempering unit). Despite these differences they all use the
circulation process. The retention time of the tempered chocolate is constant irrespective
of the chocolate consumption. This ensures a constant chocolate viscosity and allows con-
tinuous operation of such a machine if a suitable de-crystallization unit and a 3-shift heat-
ing package are available.
Hygiene design, easy maintenance and simple operation are a must today when purchas-
ing a new enrober.
In addition, there are specific further developments allowing, for instance, wet cleaning of
the machine, chocolate change within 5 minutes (two machines arranged parallel or one
behind the other) or enrobing with aerated chocolate.
If only one product is processed on an enrober line at normal rate (3 – 6 m/min), the use of
an enrober with an inboard chocolate tempering unit and a temperature controlled de-
crystallization unit is recommended because of the low space requirements and the lower
follow up costs.
A large range of accessories such as curtain roller, roller bed, turn-over shaft, hold-down
device, decoration unit as well as downstream sprinklers allow excellent adaptation to the
product related requirements. Whether to prefer an enrober with inboard tempering or out-
board tempering unit mainly depends on the type of application. If high economics, low
installation and space requirements are in the foreground of considerations, the inboard
tempering unit will always be the first choice. Its installation is simple because neither a
return pump nor a return pipeline is necessary.
Limitations here are the consumption of chocolate at limit values and increased working
rates.

4.1. Outboard enrober

This enrober is not provided with an installed tempering unit.
An outboard enrober requires approx. 1 kg/h freshly tempered chocolate per 1 mm width
of the wire belt net and must be supplied from a separate tempering machine. The size of
the necessary tempering machine is not determined by the expected chocolate consump-
tion! The worst case of operation is always the design basis for the machine builder and
that is an event of accident or failure!

If no chocolate is consumed, all the tempered chocolate supplied by the tempering ma-
chine must be melted and pumped back to the intermediate tank. If the de-crystallization
unit is too small, the temperature in the intermediate tank slowly decreases, resulting in a
worse degree of temper and enrobing quality. Lower chocolate supply temperatures to the
tempering unit require lower working settings resulting in thickening of the chocolate as
well as deposits inside the enrober which considerably limit the availability of the machine.
An additional circulation pump operates in the enrober which supplies a sufficient amount
of chocolate to the curtain trough. Depending on the design, the curtain trough can require
up to six times more chocolate circulating compared with the output of the tempering ma-
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chine. Higher viscosities in the enrobing chocolate can result in a high percentage of fric-
tion heat being produced which, of course, must be compensated by suitable temperature
settings.
The chocolate level in the sump of the enrober is kept constant by means of a level switch
which operates the return pump.

An outboard tempering unit would be preferred if:

- there are frequent changes of chocolate (for example, chocolates of

different types and colors, changes between chocolate and compound;
- a separate easily accessible tempering unit is desired;
- the chocolate consumption is extremely high;
- the working rate is above 6 m/min;
- the chocolate in the enrober is highly contaminated by dropping down
ingredients, it can be separated easily (in melted state) via a
vibration screen.
The ingredients, e.g. hazelnut slices are then discharged automatically.

Enrober with outboard tempering unit and option: vibration screen

Fig. 13

In comparison to the chocolate flow schemes in chapter 3.1. this system is equipped with a
vibratory sieve. Certain products like cereal bars may contaminate the chocolate inside the
enrober and here it is functionally essential to separate those crumbs from the returning
chocolate. However before entering the sieve the chocolate has to be de-crystallized.
Crumbs cannot be removed from tempered chocolate!

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Description of machine:
Chocolate is fed from top into the machine. A level switch installed in the enrober’s reser-
voir tank (1) controls the chocolate level, activates the feed pump for refilling, starts the
return pump to re circulate surplus chocolate to the intermediate tank and of course pre-
vents overflowing.
The chocolate in the reservoir tank is homogenized by the mixing screw and then either
fed to the bottoming pan (3) (bottom coating) or to the curtain trough (4) (overall coat-
ing) by means of the riser pump (2). The wire belt net transports cookies, bars or candies
through the machine which are covered and/or masked with chocolate while passing the
coating station. Depending on the individual setting, the blower (5) removes any surplus
chocolate from the product’s surface. The shaker (6) removes chocolate from the sides
and the licking roller (7) generates a certain layer thicknesses at the product’s bottom.
The anti-tailer device (8) installed at the discharge end of the machine removes adhering
chocolate residues from the bottom and thus prevents formation of so called tails.

Enrober without inbuilt tempering unit

Fig. 14

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4.2. Inboard enrober

The inboard machine is essentially more compact than an outboard machine. However, it
is more complicated in its design. A level switch controls the automatic re-feeding of fresh
melted chocolate in the warm tank (1). An installed mixer homogenizes the fresh choco-
late with that overflowing from the tempering trough (2). When passing the heating cy-
linder (3), the chocolate is melted completely (de-crystallized) and then passes the tem-
pering cylinder (4), where the chocolate is cooled down and the first seed crystals are
formed. The re-heating stage (5) ensures that any unstable crystals in the cocoa butter
are melted out again and thus only chocolate with a stable seed crystal structure is fed to
the circulation process. In order to cover the chocolate demand for the curtain (6) and
bottoming pan (7), two different flows of chocolate are combined directly upstream from
the curtain pump (8). Full coating requires approximately the six times as much chocolate
to circulate compared with the tempering output of the machine. The curtain pump takes in
the missing amount of chocolate from the tempering trough. It is important to note at this
point that the pump must be capable of feeding gently, because too high absorption of fric-
tion heat will reduce the stability of the tempered chocolate. Part of the chocolate leaves
the enrober with the coated product; the rest flows off the product and must be returned to
the tempering trough. A balance can be achieved only if the coating percentage does not
exceed 50 % of the tempering output. Surplus chocolate in the tempering tank flows back
into the warm tank and a new circulation process is started

Enrober with inboard tempering unit

Fig. 15

All other units such as wire belt net, bottoming pan and/or curtain trough, vibration, blower,
licking roller and anti-tailer spindle operate analogously to the description of the outboard
enrober.

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4.3. Coating equipment
The coating equipment is an extremely versatile system which can be used both to imple-
ment standard tasks and specific product requirements. The wide range of products can
be further increased enormously by the use of numerous additional applications. But even
the coating process can be extended to other product versions. Special machines have
been developed for coating with caramel, sugar icing, jelly and ice cream. In addition,
standard enrobers with minor modifications can be used for extraordinary product formats.
Beside the extension of the possibilities of use, further development of the traditional sub-
assemblies is in the foreground. The aim of these developments is to offer sanitary and
easy-to-operate machines which can produce uniform products with constant weights.
Thus, warm air heating systems are available for the inside of the machine which allow
uniform heat distribution. As an option, the blowers can be provided with a cooling function
so that the air temperature can be kept below the critical temperature of 35 °C. Parallel
and eccentric shakers are capable to remove large amounts of mass from the product.
All this shows that the enrobing technology is very flexible and offers, now as ever, devel-
opment potentials which should be utilized.

5. Chocolate moulding and aerating

Feeding of a moulding line with ingredient addition

Fig. 16

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Instead of an enrober it is also possible to supply a moulding line with tempered chocolate.
The pipeline circuit is identical and can be provided, if necessary, with branches for direct
supply, filling of a mixer or for adding flavors. All these additional units allow additions to
be made to the chocolate without contaminating the chocolate in the main circuit. Ingre-
dients such as hazelnut slices are added only on demand and retain their bizarre shape
which is typical to such nuts. Dosing is stopped in case of failure, the valves switch over to
bypass mode and the chocolate is pumped back to the tank via the de-crystallization unit.
Dry ingredients are added via a dosing machine (plate-type dosing machine, belt scale,
dosing screw, etc.) and requires the application of a mixer (tube or trough type), while fla-
vors are added by suitable dosing pumps via a static mixer.
In order to obtain an alternative texture and taste, it is also possible to aerate the choco-
late. Gas injection is used to enormously influence the specific weight. Both micro and ma-
cro aeration can be achieved depending on the size of the air bubbles. In both cases, ae-
ration takes place inside the tempering machine which therefore has to be equipped with a
special mixing head. Chocolate macro aeration is used for the production of bars and fil-
lings coarse highly visible bubble structure as in aerated chocolate with bubble diameters
of 0.5 – 2 mm. Aeration can be carried out simultaneously with the tempering process in
one operation. Suitable gases for this process include nitrous oxide (N2O) or carbon dio-
xide (CO2).The minimum specific weight which can be achieved is approx. 0.4 – 0.5
kg/dm³. Chocolate micro aeration is used for coating chocolate or moulding chocolate and
gives a fine structure with bubble sizes below 50 microns, too small to be perceived by the
consumer. Suitable gases for this process include purified air and nitrogen (N2). The spe-
cific gravities which can be achieved are very different here. Moulding chocolate can be
reduced by approx. 10 – 30 % and coating chocolate by approx. 6 – 18 % of the original
specific gravity.

6. Cooling
After leaving the enrober, the products coated with chocolate pass through a cooling tun-
nel. The chocolate coating and the filling as well are cooled down to approx. 18 °C in order
to ensure trouble-free packaging.
Three different types of heat transfer are known:

- Convection: (Heat transfer by air circulation around the product)

- Radiation: (Heat transfer by radiation exchange without air circulation)
- Conduction: (Heat transfer by contact)

The type of heat transfer to be selected depends, of course, on the product!

Filling temperature, geometrical dimensions as well as the heat transfer of the filling have
a considerable influence on the cooling down process.
Simple products, such as cookies, for example, can be cooled down in a mere air cooling
tunnel. Chocolate coated pralines with higher quality should be cooled by an additional
water bottom cooling system. Modern cooling tunnels can also be equipped with a water
bottom cooling system at a later time due to the sophisticated modular construction sys-
tem.

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A good cooling tunnel should be divided into three zones:

Zone 1: In the tunnel inlet, only sensitive heat is removed from the body and/or the choco-
late coating. Heat transfer recommended: Convection
Zone 2: After approx. 3 minutes, the crystal growth is started. Up to this point gentle cool-
ing is required. Latent heat is removed from the chocolate. Heat transfer recom-
mended: Radiation
Zone 3: Both sensitive and latent heat is removed in the tunnel outlet. Heat transfer rec-
ommended: Convection

Fig. 17

Chocolate cooling is a time-dependent and not intensity-dependent process!

Thus the following cooling times should be calculated:
- 6 minutes cooling time for pure dark chocolate
- 8 minutes cooling time for milk chocolate (EU standard)
- 12 minutes cooling time for milk chocolate (with CBE portions)

These cooling times apply if a center temperature of 22 - 24 °C is kept;

a longer cooling time should be expected at higher center temperatures!
The cooling temperature at the outlet of the tunnel should not be less than the dew point of
the ambient air; otherwise condensation will form on the product surface. Remedy:
Increasing the tunnel temperature at the outlet and reducing the flow rate.
When passing the cooling tunnel, 65 – 70 % crystals are formed in the cocoa butter. The
coating is not yet completely hardened after packing and another 30 – 35 % crystals must
be formed during final storage. This final storage is of major importance. Here, too, fat
blooming may occur due to incorrect temperature and air humidity.
A storage temperature of 15 °C and an air humidity of 60 % are recommended.
The temperature range between 18 and 22 °C should be avoided in any case!

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7. Fat blooming
Fat bloom consists of a multitude of small fat crystals, mainly of cocoa butter, which grow
out of the surface of a chocolate product. These crystals consist of fat only and not of a
mixture of cocoa butter, solid cocoa components and sugar as is the case with chocolate.
As solidified cocoa butter has a white-gray appearance, these fat crystals also have a whi-
tish-gray appearance. Small homogenously distributed fat crystals form a slightly dull gray
coating. The higher these fat crystals have grown the whiter and more unpleasant the fat
bloom will be. Fat blooming develops in two different ways. Automatic crystal conversion
on the one hand caused by incorrect and/or insufficient tempering; on the other, fat bloom-
ing may be caused by fat migration from the filling where this mostly lauric fat penetrates
the chocolate coat and presses the cocoa butter crystals out through the surface.

7.1. Fat blooming caused by automatic crystal conversion (incorrect tempering)

Cocoa butter is polymorph, i.e., it can solidify in different forms of crystals with different
melting ranges. In addition, cocoa butter is monotropic, i.e. it converts automatically and
nearly irresistibly from low melting crystal forms to higher melting forms. There are 6 dif-
ferent crystal forms. Even highly developed tempering and cooling systems can form crys-
tals of the Beta V form only in the best case. Also in these products it is possible that con-
version in Beta VI form occurs a few weeks later. Beta VI is the stable final form. It is also
called super stable crystal.
During each crystal conversion part of the fat phase can be forced to the product surface
due to softening processes (heat of crystallization, outside heat effects as well as melting
of unstable crystals) and additional contraction. However, not only crystal conversions
force fat parts to the product surface. Solidified cocoa butter still contains a considerable
portion of liquid at normal room temperature, approx. 20 %. This liquid portion also de-
pends on the type of cocoa butter used. Arriba cocoa butter is harder than Ghana and Ba-
hia cocoa butter. Within this liquid portion, fat molecules can be shifted to the surface, in
particular at high or varying storage temperatures.

7.2. Fat blooming caused by migration

Another cause of fat blooming is fat migration, where fat from the basic body migrates into
the chocolate layer and fat from the chocolate layer, in turn, is forced to the surface. Lauric
fats such as, for instance, palm kernel fat (used for baking cookies) or hazelnut oil (addi-
tion of and/or decoration with nuts, croquant products, etc.) promote fat blooming. In addi-
tion, migration is promoted by high portions of liquid fat (non-bound fats) in the basic body,
e.g. nut oils and higher liquid fat portions in the chocolate layer, e.g. at high storage tem-
peratures.

7.3. Conditions to prevent and/or delay fat blooming

1. Proper pre-crystallization of the chocolate mass to form highly melting Beta V crystals.
Slight over-crystallization is better than under-crystallization.
2. Adapted cooling profile with convection cooling in the inlet area, smooth and gentle rad-
iation cooling up to the center of the tunnel so that the prevailing cocoa butter portion
solidifies in the highly melting Beta V crystal form; then more intensive convection cool-
ing to noticeably cool down the chocolate coating and to reduce the residual liquid por-
tion. Longer total cooling times are of advantage. When the mass “starts solidification”,
the chocolate temperature shall not already be cooled down below the crystallization
temperature of approx. 22 °C (refer also to measuring the degree of temper ).
3. Ideal storage conditions, i.e. relatively low temperature, e.g. 10 – 15 °C to keep the liq-
uid fat portion in the chocolate coating and basic body low. In addition, the storage tem-

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CHOCOLATE PROCESS TECHNOLOGY
perature should be kept constant to exclude movement in the crystal structure due to
heat expansion.
4. Minimizing the portion of liquid fat in the chocolate by using hard cocoa butter types and
minimizing the liquid fat portion in the basic body, e.g. by limiting the nut fat portion.
5. Use of fractionized milk fat also in the dark chocolate, e.g. 2 %, because mixed crystals
of cocoa butter and milk fat react more slowly during crystal conversion. When using
fractionized milk fat, however, only highly melting fractions should be used, these are
the highly melting portions of the milk fat.
6. Ideal basic body temperature at the inlet of the enrober: 22...24°C.
7. Bottom cooling until the chocolate begins to solidify, approx. 15 °C, after beginning of
solidification approx. 10 °C. The high-gloss products should loosen from the belt, no fat
film shall be left on the belt.

8. Resume
Tempering is an extensive physical process which can be handled more easily and more
reliably due to the continuously evolving tempering and cooling systems. The system can
be monitored continuously at the Tempergraph (supplied as an option) and – in the near
future – controlled via suitable evaluation of the determined data. In connection with the
highly developed control system, availability and operation of the machine can be further
optimized. Even the quality of a proper product, whether coated or moulded – will profit.
Unfortunately, no single machine is decisive for the course of process of an overall system
but the interaction of the individual components, which have to be precisely adapted and
balanced to each other. As has always been the case, the understanding and certain iden-
tification with the existing machinery are included in the tasks of the operator, who will also
determine the efficiency of a system.
Fat blooming has been and will remain a highly topical subject where the cause is migra-
tion in 95 % of the occurrences and not incorrect tempering. Thicker product bottoms, in-
sulation layers between filling and coating, optimization of the filling recipe, keeping the
recommended cooling times and/or cooling temperatures as well as longer cooling times
will minimize this issue; however, exact balancing of investment costs and the shelf life of
the product which can be achieved is necessary here.

9. Literature

- Chocolate Processing,
Lecture + training 2006, Karsten Richter (Sollich)
- Tempering and aeration,
Lecture, Inter-Praline 2005, Volker Bäumer (Sollich)
- Lebensmittel Praxis,
Verlag GmbH, Neuwied und Bundesverband der deutschen Süßwarenindustrie
e.V., Bonn (technical field chocolate) (1991); ISBN 3-88688-227-6
- Moderne Schokoladentechnologie,
S.T. Beckett (1990), B. Behr’s Verlag, Hamburg ISBN 3-925673-76-8
- Das große Buch der Schokolade,
Schuhmacher, Forsthofer, Rizzi (1995) Tebner Edition; ISBN 3-7742-1919-2

Bad-Salzuflen, June 9, 2008 Karsten Richter

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