COCOA PROCESSING PLANTSTURN-KEY SOLUTIONS

Liquor tempering and blockingThe cocoa liquor is tempered and packed in 25 kg carton boxes with plastic inner liner. The cocoa liquor is fed to a dosing valve via a pre cooler and a tempering machine. Filling of the boxes is fully automatic and supply and discharge of the carton boxes is realised by a conveying system with integrated load cells for exact weighing and filling of the boxes.

Cocoa butter pressingIn the Duyvis cocoa butter presses the butter is separated from the cocoa cake. This press achieves a high pressing result in combination with good liquor preparation, liquor filling pump and the hydraulic unit.

During pressing the butter is separated through filter screens in the counterpots. Butter runs down butter dripping trays into a central butter channel and the butter is collected in the butter discharge vessel. Cakes are dropped in a cake conveyor. As soon as the cakes drop into the trough, the disc pushed them in the direction of the cake breaker. Butter is collected and can be send to the crude butter storage tanks. Crude butter is pumped through an automatic butter filter into clean butter storage tanks.

Cocoa butter filtration and storageAfter the butter is pumped out of the discharge vessel, it is pumped into the crude butter storage tank. From this tank, the crude butter is pumped to and through the cocoa butter filter. The cocoa butter filter system consists of a pressure vessel in which filter elements are placed. These filters are cleaned per time interval by an air pulsation. The cocoa butter is pumped in the vessel and pressed through the filter elements under low pressure. The residue sinks to the bottom of the vessel and is discharged per time interval by means of a slurry

pump. This slurry will be pumped back to the liquor storage tanks. The clean butter from the butter filter is discharged to the clean butter storage tanks.

Butter tempering and blockingThe cocoa butter is tempered and packed in 25 kg carton boxes with plastic inner liner. The cocoa butter is fed to a dosing valve via a pre-cooler and a tempering machine. Filling of the boxes is fully automatic and supply and discharge of the carton boxes is realised by a conveying system with integrated load cells for exact weighing and filling of the boxes.

Cake handlingThe cake which comes from the cake breakers of the cocoa butter presses is collected and transported to a cake packaging system or the pulverising plant. Usually the cake kibbles arecooled and stored before packaging or pulverising. Packaging of cakes can be done in big bags and/or paper bags. Before the packaging machines a metal detector with reject valve will be installed.

Cake pulverising and powder packagingThe cake kibbles are transported to the pulverising plant via a metal detector. From the metal detector outlet, the cocoa kibbles are ground in a classifier mill into powder. The cocoa is transported through the mill by means of conditioned and cooled air. During the grinding the powder is cooled since the design of the mill is such that the powder is surrounded by cool air. The classifier assures that the ground powder has the required fineness. After the initial pulverising step, the powder is further cooled down and stabilized before packaging in big bags and/or paper bags.

Duyvis cake pulverising

Duyvis cocoa pressesDuyvis cocoa presses

COCOA PROCESSING PLANTSTURN-KEY SOLUTIONS

WHEN DUYVIS TOOK OVER LEHMANN ,THE WORLD OF TURN KEY-PLANTS CAME INTO A NEW DIMENSION. WITH THE “TRADITIONAL” APPROACH OF LEHMANN WE HAVE THE BEST PROCESS OF FLAVOR DEVELOPMENT. WITH THE NEW DESIGN DRUMROASTER WE CAN ALSO FULLFILL THE NEEDS OF THE CUSTOMER WHICH GOES FOR THE HIGHEST CAPACITY IN COMBINATION WITH GOOD QUALITY.

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When Duyvis took over Lehmann, the world of turnkey-plants came into a new dimension. With the 3 principles of roasting, including the new designed drum roaster, we can fulfill all the needs of customers which go for the highest capacity in combination with super quality.

CleaningCocoa processing starts with removing contaminations in the delivered raw cocoa like stones, sand, dust, wooden parts, strings, iron parts and other foreign bodies.

Continuous bean roasting approachThe Lehmann bean roasters have many advantages compared to the other systems. The beans are going through the roaster by gravity. The beans are captured in layers and every cycle time, one small batch is “dumped” into the next. The hot air is coming from the bottom. By this, every bean is getting the right and the same treatment. So every bean is roasted equally. By bean roasting the flavors are all staying in the nib. The shell is protecting the nib against over roasting. Beside of this after roasting the shell is very easy to remove. The Lehmann bean roasting method prevents butter migrating from the nib to the shell. Bean roasting is preferred in chocolate producing plants. In the continuous bean roasting approach, the winnowing takes place after the roaster. Before winnowing the beans are sterilized by steam.

Lehmann cocoa processing plant

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Breaking and WinnowingIn terms of the breaking and winnowing technology, Lehmann is offering a unique design worldwide. In the high end version of the winnowing machines, three steps of breakers are cracking the cocoa beans. As the revolution speed of the breakers is increasing from one step to the next one, and broken beans are sorted out in between, every single cocoa bean is only charged with the energy that is really necessary to break the shell. Every size of nibs and shell is running through a vertical winnowing duct, where the turbulent air flow is taking the lightweight shell, while the heavy nibs are falling down to the collecting conveyor. Smallest amount of shell in nibs is providing a high quality cocoa liquor later on. Smallest amount of nibs in shell is providing a minimum of wasting the valuable cocoa nibs with the flow of shell. The unique treatment on the Lehmann technology is providing cocoa nibs, fully developed in aroma, almost free of any bacteria and only charged with a minimum of shell residues, ready for milling and refining to highest quality cocoa liquor.****

Nib roasting approachNib roasting can be done in 2 ways: Continues or Batch.When going for nib roasting first the shell has to be removed. In this case the Lehmann pre-dryer is used. The dryer gently loosens the shell from the kernel. Breaking and winnowing see above.

After cleaning and winnowing then alkalizing takes place.The last 30 year nib alkalization is the most used method. It givesthe most flexible system regarding flavor, color and pH influence.The new Lehmann special alkalizing system is able to threat nibs up to very high moisture content. First drying it in the alkalizer, and feeding the roaster with pre-dryed nibs results in perfect color and flavor development. The alkalizer is capable of handling moisturized nibs up to 30%. pH values from >8 can be achieved. High pressure can be applied. After this the water has to be steamed out. Under pressure can be used to fasten the drying process.

COCOA PROCESSING

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Continuous nib roastingThe Lehmann continues nib roasting principle has several advantages. The machine is foreseen with using turning layers. With this system the machine is staying clean. The beans (or nibs) are all threated the same way in small batches. Because of this a very even, flavor developing, product result. this positive effect was already known in the chocolate industry. But also for producing cocoa it is a very attractive way of roasting concerning energy consumption, flexible flavor development. The colors are not changed in this way at all. The continuous nib roaster can develop the same flavour as a drum roaster. High acid and non-fermented beans can be upgraded to a less acid flavor. More parameters are effectible which results in a, less temperature dependent, and so more flexible system. The system can be adapted to each, even extraordinary, feeding material. It is ideal for 24/7 production. Exhausted air low concentrated with low temperature and with fewer odors by a lower temperature. The nib roaster has a cooling section to cool down the nibs to an ideal temperature to feed it into the liquor grinding.

Batch nib roasting In batch roasting the boast batch will be led into the drum roaster. Any preferred recipe can be realized. The Lehmann drum roaster is a total new design. It combines all the benefits of high capacity nib roasting with high quality taste development. After the batch time is finished the batch will be fed into a cooler. The new designed cooler is having a high capacity. The cooler will cool down the nibs to an ideal temperature to feed it into the liquor grinding.

Grinding of nibs to cocoa liquorThe roasted nibs are grinded in several stages to a final fineness of about 99.5% < 75 µm. First the nibs are pre ground in a beater blade mill. The pre-ground liquor will be further processed for final size reduction by pumping it through several ball mills. After the last ball mill the liquor will be sieved to remove the too large particles which have been slipped through. The cocoa liquor is pumped to the liquor storage tanks from where the liquor can be further processed.

Wiener cocoa liquor grinding line

Royal Duyvis Wiener B.V. P.O. Box 101540 AA Koog a/d Zaan

Schipperslaan 151541 KD Koog a/d ZaanThe Netherlands

P. +31 75 6 126 126F. +31 75 6 158 377

sales@duyviswiener.comwww.duyviswiener.com

FROM COCOA BEAN TO CHOCOLATE

EXCELLENT INNOVATIONS. GLOBAL SERVICES.

ROYAL DUYVIS WIENER AND F.B. LEHMANN COMBINES ALMOST 200 YEARS OF INNOVATIVE EXPERIENCE IN PROCESS INNOVATIONS, MACHINE CONSTRUCTION AND MAINTENANCE SERVICES. A UNIQUE COMBINATION OF EXPERTISE FOR WHICH ROYAL DUYVIS WIENER B.V. IS KNOWN WORLDWIDE. THE HEAD OFFICE IS SITUATED IN THE VERY HEART OF THE WORLD FAMOUS DUTCH COCOA AND COCOA BUTTER PROCESSING INDUSTRY. F.B. LEHMANN GMBH IS SITUATED IN AALEN GERMANY.

Competitive in cocoa and chocolate equipment The core business of Duyvis (1885), Wiener (1899) and F.B. Lehmann (1834) is clear: the engineering, manufacturing and installation of production machinery for the cocoa and chocolate industry. A solid foundation of cutting edge innovation and dedicated development teams results in an impressive level of service. Across the world Duyvis, Wiener and F.B. Lehmann’s industrial solutions are hard at work 24/7 in every industrial environment, particularlyin the cocoa and chocolate industry.

With F.B. Lehmann, Royal Duyvis Wiener is able to supply a variety of innovations from Lehmann roasting (nibs and beans) and Wiener grinding to the Duyvis cocoabutterpresses and powder technology, as well as supply equipment to produce chocolate in the traditional way (Lehmann 5-roll refining) up to the latest all-in-one Wiener chocolate technology. The group of companies offers solutions for the complete process from cocoa bean to chocolate.

Wiener and F.B. Lehmann joining DuyvisWiener has been part of the Duyvis Group since 2004. Globally acknowledged as an innovative manufacturer and supplier of cocoa and chocolate production machinery; stand alone or turnkey. A valued partner for both the cocoa and chocolate and ice cream, bakery and confectionery industries. F.B. Lehmann GmbH is the latest acquisition (2010) of Royal Duyvis Wiener.

F.B. Lehmann is well known for its bean intake, winnowing, roasting and horizontal grinding equipment, as well as its unique machinery for state-of-the-art 5-roll refiners. The unique combination of companies and technologies is a guarantee of the highest industry standards and excellent service.

Guaranteed continuity The Duyvis Wiener Lehmann team also modifies, repairs and maintains every type of cocoa and chocolate industrial installation globally. There is no problem so challenging that the Royal Duyvis Wiener team cannot provide a suitable solution, either preventative or curative. The result is an undisrupted production process minimizing down time and providing optimum yields.

Remarkable developmentThe engineers, technical and process development experts at both Royal Duyvis Wiener and F.B. Lehmann work closely and constructively together on intelligent process and product innovations. The laboratories in Koog aan de Zaan (The Netherlands) and Aalen (Germany) provide all of the facilities imaginable for testing food products in general and cocoa, chocolate and confectionery products in particular. Know-how which is directly accessible from an extensive process database.

Give us your challenge! Give us your challenge and we will help improve your quality and reduce your costs to produce cocoa, compound and chocolate.