Beckett's Industrial Chocolate Manufacture and Use

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

'The fifth edition of this invaluable book continues to be the definitive work on all things to do with cocoa and chocolate... The level of detail is well judged, offering explanation, practical advice and plenty of technical and scientific detail in each chapter, but also providing cross references and an excellent bibliography at the end of each chapter to allow further investigation of topics. The writing style is lucid, drawing the reader into the subject and exciting interest and further reading. In addition to the text, there are many useful and interesting photographs, tables, drawings and charts which enhance the discussions and illustrate important points ... This is a book which justifies its place at the hand of anyone involved in cocoa and chocolate. There will be very few in the industry whose knowledge and experience are so comprehensive as not to find useful information between its covers.' Confectionery Production, November 2017

• Contributors, xxivPreface, xxxv1 Traditional chocolate making, 1Stephen T. Beckett1.1 History, 11.2 Outline of the process, 21.3 Concept of the book, 7References, 82 Cocoa beans: from tree to factory, 9Mark S. Fowler and Fabien Coutel2.1 Introduction, 92.2 Growing cocoa, 102.3 Fermentation and drying, 202.4 The cocoa supply chain, 252.5 The cocoa value chain: long‐term perspectives and challenges, 312.6 Quality assessment of cocoa, 342.7 Types and origins of cocoa beans used in chocolate, 42Conclusions, 47References, 48Appendix: Abbreviations, acronyms and organisations, 493 Production of cocoa mass, cocoa butter and cocoa powder, 50Henri J. Kamphuis, revised by Mark S. Fowler3.1 Introduction, 503.2 Cleaning of cocoa beans, 503.3 Removal of shell, 523.4 Breaking and winnowing, 533.5 Alkalisation, 543.6 Bean and nib roasting, 543.7 Cocoa mass (cocoa liquor), 583.8 Cocoa butter, 623.9 Cocoa press cake and cocoa powder, 65Conclusion, 69Appendix: Manufacturers of cocoa processing equipment, 70References and further reading, 704 Sugar and bulk sweeteners, 72Christof Krüger4.1 Introduction, 724.2 The production of sugar, 724.3 Sugar qualities, 744.4 The storage of sugar, 754.5 Sugar grinding and the prevention of sugar dust explosions, 774.6 Amorphous sugar, 804.7 Other sugars and bulk sweeteners, 814.8 Physiological characteristics of sugars, bulk sweeteners and special polysaccharides, 894.9 The sweetening power of sugars and bulk sweeteners, 924.10 Other sensory properties of sugars and bulk sweeteners, 934.11 Solubilities and melting points of sugars and bulk sweeteners, 954.12 Maximum conching temperatures of chocolate masses with different bulk sweeteners, 954.13 Separate conching process for “no sugar added” chocolates, 974.14 Pre‐ and probiotic chocolates, 97Conclusions, 98References, 985 Ingredients from milk, 102Ulla P. Skytte and Kerry E. Kaylegian5.1 Introduction, 1025.2 Milk components, 1035.3 Milk‐based ingredients for chocolate, 114Conclusion, 131References, 1316 Chocolate Crumb, 135Martin A. Wells6.1 Introduction and history, 1356.2 Benefits of milk crumb, 1366.3 Typical crumb recipes, 1376.4 Flavour development in chocolate crumb, 1376.5 Sugar crystallisation during crumb manufacture, 1416.6 The structure of chocolate crumb, 1426.7 Typical crumb processes and equipment, 1456.8 Effect of the crumb process upon the crumb properties, 1506.9 Changes to crumb during storage, 150Conclusion, 151References, 1527 Properties of cocoa butter and vegetable fats, 153Geoff Talbot7.1 Introduction, 1537.2 Cocoa butter, 1547.3 Cocoa butter equivalents, 1627.4 Lauric cocoa butter substitutes, 1767.5 Non‐lauric cocoa butter replacers, 1797.6 Vegetable fats with specific properties, 181Conclusion, 182References and further reading, 1838 Flavour development in cocoa and chocolate, 185Gottfried Ziegleder8.1 Introduction, 1858.2 Fermentation, 1858.3 Drying, 1908.4 Roasting, 1938.5 Conching, 2018.6 Dark chocolate and milk chocolate, 2058.7 Flavour release in chocolate, 208References, 2099 Particle size reduction, 216Gregory R. Ziegler and Richard Hogg9.1 Introduction, 2169.2 Principles of fine grinding, 2179.3 Grinding equipment, 2209.4 Cocoa nib grinding, 2249.5 Chocolate refining, 2269.6 Particle size reduction and chocolate flow properties, 2339.7 Particle size and sensory properties, 237Conclusions, 238References, 23910 Conching, 241Stephen T. Beckett, Konstantinos Paggios and Ian Roberts10.1 Introduction: the reason for conching, 24110.2 The principles of conching, 24210.3 The three phases of conching, 24810.4 Conching machines, 251Conclusion, 272References and further reading, 27311 Chocolate flow properties, 274Bettina Wolf11.1 Introduction, 27411.2 Non‐Newtonian flow, 27511.3 Presentation of viscosity measurements, 27811.4 Single point flow measurement, 27911.5 Rotational viscometers, 28211.6 Vibrational viscometers, 28511.7 Oscillatory rheometers, 28511.8 Sample preparation and measurement procedures, 28611.9 Factors affecting the flow properties of chocolate, 28911.10 Advanced methods to characterise chocolate flow behaviour, 295Conclusions, 296Acknowledgements, 296References, 29612 Bulk chocolate handling, 298John H. Walker12.1 Introduction, 29812.2 Viscosity and viscometry, 29812.3 Pump sizes, 30112.4 General criteria for choosing a pump, 30112.5 Types of pump, 30212.6 Pipeline pigging, 30712.7 Storage of liquid chocolate, 30812.8 Jacketed pipe work, 30912.9 Valves, 31112.10 Contamination removal, 312Conclusions, 313Acknowledgements, 31313 Tempering, 314Erich J. Windhab13.1 Introduction, 31413.2 Physics of cocoa butter crystallisation, 31513.3 Chocolate tempering technology, 31613.4 Measurement of temper and its related characteristics, 31813.5 Tempering processes, 32313.6 Types of tempering machine, 33113.7 Properties of CBCS tempered chocolate, 34613.8 Other methods of tempering, 352Conclusion, 352Acknowledgements, 353References and further reading, 353Appendix: Machinery manufacturers, 35514 Moulding, enrobing and cooling chocolate products, 356Michael P. Gray, revised and updated by Ángel Máñez-Cortell14.1 Introduction, 35614.2 Moulding, 35614.3 Enrobing, 383Conclusions, 398Acknowledgements, 398References and further reading, 39815 Non‐conventional machines and processes, 400Dave J. Peters15.1 Introduction, 40015.2 Ultrasound, 40015.3 High shear/low temperature crystalliser, 40215.4 High pressure temperer, 40415.5 Extrusion, 40515.6 “Single shot” depositors, 41315.7 Aeration of chocolate, 41815.8 Cold forming technologies, 42115.9 Paste conching, 428Conclusions, 428References, 42916 Chocolate panning, 431Marcel Aebi, revised by Mark S. Fowler16.1 Introduction, 43116.2 Panning methods, 43216.3 The process of chocolate panning, 43416.4 Packaging and storage, 44416.5 The panning department, 445Conclusions and future developments, 449References and further reading, 449Appendix: Manufacturers of panning equipment, 44917 Chocolate rework, 450Edward Minson and Randall Hofberger17.1 Introduction, 45017.2 Rework, 45017.3 Constraints, 45117.4 Economics, 453Conclusions, 455References, 45518 Artisan chocolate making, 456Sophie Jewett18.1 Introduction, 45618.2 Chocolate trends in mature markets, 45618.3 Selecting the right product lines to make, 45818.4 Critical considerations, 46418.5 Taking products to market, 46918.6 Selecting the right chocolate, 47318.7 Hand‐tempering techniques, 474Conclusions, 478Further reading, 47819 Chocolate compounds and coatings, 479Stuart Dale19.1 Introduction, 47919.2 What are chocolate compounds and coatings?, 47919.3 Manufacture of compounds and coatings, 48219.4 How compounds are used, 48519.5 Benefits of using chocolate compounds, 48519.6 Trans fatty acids in chocolate compounds, 48819.7 Environmental aspects, 48919.8 Summary of the properties of compound coatings, 48919.9 The future of compound coatings, 489References and further reading, 49120 Recipes, 492Edward G. Wohlmuth20.1 Chocolate tastes in different countries, 49220.2 The basic ingredients, 49420.3 Conching to develop flavours, 49520.4 Chocolate recipes, 496Conclusions, 50821 Sensory evaluation of chocolate and cocoa products, 509Meriel L. Harwood and John E. Hayes21.1 Introduction, 50921.2 Types of sensory tests, 51021.3 Special considerations, 51321.4 General considerations/good sensory testing practices, 517Conclusions, 519References, 51922 Nutritional and health aspects of chocolate, 521Joshua D. Lambert22.1 Introduction, 52122.2 Macronutrients, 52222.3 Vitamins and minerals, 52322.4 Flavanols and proanthocyanidins, 52322.5 Methylxanthines, 52422.6 Cardiovascular disease, 52422.7 Obesity and metabolic syndrome, 52522.8 Inflammation, 52622.9 Neuroprotective and cognitive effects, 527Conclusions, 529Acknowledgements, 529References, 52923 Quality control and shelf life, 532Marlene B. Stauffer23.1 Introduction, 53223.2 Finding the perfect bean, 53223.3 Cocoa bean preparation on arrival, 53523.4 Cocoa bean cleaning, 53523.5 Roasting of cocoa beans, 53723.6 Cocoa nib grinding, 53923.7 Cocoa butter pressing, 54123.8 Cocoa powder, 54223.9 Chocolate manufacturing, 54223.10 Specifications, 54723.11 Tempering, 54823.12 Shelf life of finished confections, 54924 Instrumentation, 555Ulrich Loeser24.1 Introduction, 55524.2 Production measurement technology – in‐/on‐line, off‐line, 55724.3 Laboratory analysis, 58424.4 Summary of important analytical procedures in a typical quality assurance laboratory, 594Conclusions, 595Acknowledgements, 596References and further reading, 59625 Food safety in chocolate manufacture and processing, 598Faith Burndred and Liz Peace25.1 Introduction, 59825.2 The importance of food safety management in chocolate processing, 59825.3 HACCP and prerequisite programmes, 59925.4 Physical hazards, 59925.5 Chemical hazards, 60425.6 Microbiological hazards, 60725.7 Allergen hazards, 614Conclusions, 617References, 61726 Packaging, 620Carl E. Jones26.1 Introduction, 62026.2 Confectionery types, 62026.3 Flow wrap machinery and sealing, 63126.4 Materials, 63326.5 Sustainability, 64626.6 Portion control, 64826.7 Quality control and environmental criteria, 651References and further reading, 65327 The global chocolate confectionery market, 654Jonathan Thomas27.1 Background, 65427.2 The global chocolate market, 65627.3 Industry supply, 65727.4 Global production and consumption of chocolate, 65927.5 Reasons for eating confectionery, 66227.6 The marketing of confectionery, 66527.7 The regulatory position, 669Conclusions, 672References, 67428 Legal aspects of chocolate manufacture, 675Richard Wood28.1 Introduction, 67528.2 International standards – the Codex Alimentarius, 67528.3 European standards, 68028.4 United States of America, 68628.5 Canada, 68928.6 BRIC markets, 69028.7 Use of additives, 69028.8 Labelling, 692Conclusions, 693Further reading, 69429 Intellectual property: Protecting products and processes, 695Patrick J. Couzens29.1 Introduction, 69529.2 Patents, 69529.3 Trade marks, 70829.4 Designs, 71129.5 Copyright, 71229.6 Contracts and agreements, 71329.7 Trade secrets, 71529.8 Defensive publication, 71729.9 Strategy, 71729.10 Enforcement, 72329.11 How to find help, 724Conclusions, 725References, 725Appendix: Useful web addresses, 72630 Future trends, 727Stephen T. Beckett30.1 Past predictions, 72730.2 Present position, 72930.3 Possible future trends, 731References, 732Glossary, 734Useful physical constants, 737Index, 739