ERG+£N CHOCOLATE

8/12/2019 ERG+N CHOCOLATE

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T.CUNIVERSITY OF GAZIANTEP

FACULTY OF ENGINEERING

FOOD ENGINEERING

2010 - SUMMER PRACTICE JOURNAL

Prepared !" F#L#Z $Z


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CONTENTS

Company Name And Location 2

A Brief History Of The Company... 2

Number Of Engineers And or!ers... 2

Organi"ation #iagram............ $

%ntroduction. $&'

About The Choco(ate )roduction *&++

E,uipments -sed %n Choco(ate )roduction. ++&+*

ateria( And Energy Ba(ances... +*&+/

0ua(ity Contro( Test. +/&21

Ana(ysis #one On Choco(ate a3 ateria(s 2+

Ana(ysis #one %n Chemistry Laboratory.. 2+&2$

Ana(ysis #one %n icrobio(ogy Laboratory. 2$&2'

edia4 %ncubation Temperature 5 Time Of The Bacteria Ana(ysed... 2*

ethod -sed To #etect The icroorganisims.... 2*&26

Cost Ana(ysis ....... 27

Conc(usion ... 27&28

Appendi9 ..... 28

eferences... $2

2


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COMPANY NAME AND LOCATION

ComponyName: Erg;n Choco(ate afer And Bubb(e


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ORGANIZATION DIAGRAM

INTRODUCTION

>ummer practices is the one of the most important part of an engineers education 3herethe engineer may train practica( s!i((s for app(ications of hisher theoretica( bac!ground tothe industria( sca(e processes and the obPecties 3hi(e designing or running an industria(

process can be obsered. %t gies a chance to (earn about the practica( app(ications.This practise time proided me to (earn about !inds of ana(ysises4techno(ogy4my abi(ity4toobsere the human ships in business (ife.A(so it 3as e9pected to obsere a(( the processesand ana(ysises.

% had performed my summer practice at Erg;n choco(ate =actory.

y subPects to obsere during training 3ere

)rocess machines and e,uipments

0ua(ity Contro(

E


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Operation p(ans

)roduction procedure

Net 3eight contro(

Contro( points and critica( contro( points

e3or! hand(ing

C(eaning procedures

A%OUT T&E C&OCOLATE PRODUCTION

Choco(ate )roduction =(o3 Chart:

Cocoa ass i(! po3der

Cocoa Butter >ugar and =(aors

Cocoa Butter Lecithin

ine ice

)istachio

Nut

A(mond

)ac!aging

ateria(

*

MI'IN

REFINING

CONC&ING

TEMPE

MOULDING ENRO%ING

PAC(AGINGPAC(AGING

STORAGE


6/34

Raw Materials:

There are a (ot of ingredients of choco(ate but the most essentia( ra3 materia( of it is

cocoa. Because three main ra3 materia(s of choco(ate is obtained from cocoa. These are

cocoa mass4 cocoa butter and cocoa po3der.

Cocoa Beans

QC(eaningQ

)asteuri"ing and oasting

Qinno3ing >he((

QCocoa nibs

Q


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C)*)a Ma++"=or a typica( choco(ate recipe4 the cocoa mass is one of the maPor components.

%t constitutes appro9imate(y '1K of dar! choco(ate and +*K of mi(! choco(ate.

C)*)a P),der: The other constituent of choco(ate is cocoa po3der. %n fact4 cocoa po3der

containing choco(ate is ca((ed compound. %t is obtained by refining or mi((ing of cocoa press

ca!e. Cocoa po3der is used in instant drin!s4 and in spread products. And at the same time4

cocoa po3der is fi((ed in pac!ages and so(d as a product.

C)*)a %er"The ne9t most important component is cocoa butter. %t is obtained by the fatpressing of cocoa mass. %t is a b(end of trig(ycerides. %t may crysta((i"e in arious shapes

3hich are a(pha4 gamma and beta forms. %t is so(id at 21C and aboe $*C it is (i,uid and has

ye((o3 co(or. >tabi(ity of cocoa butter increases from gamma to beta + form. %f it is coo(ed too

fast4 an unstab(e mi9ture of these forms are formed. Therefore tempering is app(ied in order to

obtain the most stab(e form.

The other important ra3 materia( is the mi(! po3der group 3hich is used in mi(!choco(ates. These are 3hey po3der4 s!im mi(! po3der and 3ho(e mi(! po3der. Thes

materia(s gie a mi(!y s3eet taste to choco(ate and change its co(or from dar! bro3n to (ight.

%n some instances4 3hey po3der may rep(ace s!im mi(! po3der because of its commercia(

adantage. #ue to the mi(! fat present in po3ders4 mi(! choco(ates are softer than dar! ones

and sometimes they may me(t in your fingers before you eat it.

A(so (ecithin can be considered as an ingredient and it is an emu(sifier. %t is used for

the contro( of iscosity of choco(ate. %t is ab(e to stabi(i"e the emu(sion of sugar4 fat and cocoabutter. %t is soy (ecithin. The addition of 14+&14$K soy (ecithin has the same iscosity reducing

effect as oer ten times this amount of cocoa butter. This fact is of great commercia(

importance. Because cocoa butteries the most e9pensie ingredient. But 3e can not use

(ecithin as much as 3e 3ant in order to decrease the cost of product. Because if (ecithin

percentage e9ceeds 14$R14*K4 the choco(ate becomes thic!er. Other than soy (ecithin4

JNSammonium phosphatide4 )


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%n some products such as b(ac! and ga(ac S3hite mi(! choco(ate4 a butter ca((ed ugarLecithin

Mixing:

Crysta( sugar4 cocoa butter4 cocoa (i,uor Scocoa mass are brought together to produce

a homogenous choco(ate mi9. A ma(engeur of traditiona( design consists of t3o ertica((y

positioned re(ating heay ro((ers standing on a hardened4 hori"onta(4 heated bed.

#uring (oading4 the me(angeur shou(d be heated to '1VC the mi9ing operation is carried out at*1R61VC .

efunds Sreusab(e materia(s obtained during production4 ani((in are added into the

tan! before the mi9ing ta!es p(ace. The temperature time combination is an important

parameter in order to adPust the iscosity4 3hich is crucia( during carrying through the bands.

Pre-refining:

The pre&refining unit consists of t3o ro((ers 3hich bring the si"e of the materia(appro9imate(y to +*1 microns. )re&refining assures the improement of the homogeneity

8


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characteristics of the mass4 the reduction of the sub fine partic(es4 the reduction of the ,uantity

of oer(arge partic(es4 and a(so the increase in the efficiency of the refining process.

Refining:

efining ino(es the crushing4 abrasion4 attrition and shearing of cocoa and sugar

fragments to produce a product4 3hich has the desired partic(e si"e. #uring refining the

partic(e si"e fa((s and the tota( surface area of the partic(e increases. %ncreases in surface area

in choco(ate partic(es re,uire the addition of mare cocoa butter to maintain the same f(o3

properties. %t fo((o3s that an increase in the refining 3i(( ineitab(y change the behaior of the

choco(ate for (ater stages in processing. >o oer&refining can be cost(y.%n I(!er refiners consist of * ro((ers. %n the * ro((er mi((4 used during refining each

ro((er operates at different speeds4 arranged to cause the choco(ate to f(o3 form the (o3est ro((

ertica((y up3ards to the top ro((. The (o3est ro(( is operated at the s(o3est speed. Each ro(( is

adPustab(e for spacing. By the time the choco(ate is discharged from the top ro(( it is trae(ing

eight times faster than it did on the (o3est ro((.

There are three refiners in order to bring the si"e of the mass from +*1 microns to

near(y $1 microns. The fie ro((ers 3hich form a simp(e refiner are set to different

temperatures.

efined choco(ate is remoed from the top ro(( by accurate(y positioned scraper b(ades

and discharged on to coneyer be(ts. The po3dery nature of the mi9 is due to the (arge

increase in the surface area that has ta!en p(ace in comparison to the surface o(ume that is

occupied by the fat.

Conching:

The process of conching is primari(y one of the f(aor dee(opments4 by remoing the

undesirab(e o(ati(e acidic components remaining after fermentation and by the chemica(

changes that ta!e p(ace in the f(aoring components in the choco(ate mi9.

Other secondary effects are:

& The remoa( of moisture from the mi9

& A smoothing of the sharp edges of the sugar crysta(s

& Co(or changes arising from fat emu(sification

& Changes in iscosity of the mi9

/


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& Through mi9ing 3hich brea!s up the aggregates of sugar and cocoa partic(es

These are $ steps in conching: #ry conching4 )(astici"ing4 Li,uid conhcing

+. #ry conching: =i((ing the f(a!y choco(ate coming from the ro(( refiners4 s(o3

rotation speed4 remoing moisture and o(ati(es at moderate temperature and ris! of grit

formation at too high temperature and high 3ater content.

2. )(astici"ing: High rotation speed4 increase of temperature4 consistency turning from

f(a!y to isco&p(astic.

$. Li,uid conching: Adding of butter and (ecithin on high rotation speed and reersed

direction4 coo(ing do3n4 ready to empty.

Before the choco(ate is fed to the conches4 cocoa butter is added into the conches and

after the choco(ate is fed4 conching ta!es p(ace bet3een +R+2 hours Saccording to the desired

product at *1R81Vc. Wust before the conching process ends4 (ecithin is added 3hich is an

emu(gator.

Tempering:

Tempering is a method of inducing cocoa butter to crysta((i"e in a stab(e form in the f(uid

choco(ate mass. The process is necessary to ensure a (ong she(f&(ife. A fau(t !no3n as b(oom

can dee(op. This appears in t3o forms:

& #ee(opment of crysta(s of unstab(e fat on the surface of the choco(ate

& >ugar crysta((i"ation on the surface of the product

=at b(oom formation occurs more readi(y 3ith pain choco(ate than in mi(! choco(ate

because of the presence of mi(! fat and mi(! phosphatides in the (atter.

The hand(ing of choco(ate during tempering and enrobing is goerned by a number of

factors:

& Composition of the choco(ate

& Uiscosity of the choco(ate

& Temperature of use

& >tate of temper

Moulding:

+1


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The production of choco(ate she((s for subse,uent fi((ing is achieed by inerting

choco(ate fi((ed mou(ds. =i((ed bar production by inersion ino(es preheating of the

mou(ds4 tempering of the choco(ate4 depositing into the mou(d inersion4 remoa( of the

e9cess choco(ate by heated 3ipers4 fi((ing4 bottoming and ePection.

adiant heaters are used to raise the temperature of the mou(d before receiing its

charge of choco(ate. The choco(ate is tempered and deposited in the indiidua( mou(ds by

transfer through piston b(oc!s and directiona( no""(es. As 3ith a(( she(( p(ant4 the temperature

of the choco(ate and the mou(ds is critica( at this stage and shou(d be contro((ed. The mou(ds

are then passed oer ibrators to remoe any entrapped air4 and rotated to produce the thin

she(( of choco(ate. The mou(ds are then passed through step chi((ing units 3hich produce s(o3

coo(ing thereby preenting the crac!ing of the she((s. E9cess choco(ate is remoed by heatedscraper b(ades.

Three points must be obsered 3hen deriing a fi((ing for choco(ate she((s:

Xoisture content must be contro((ed

XThe iscosity of the fi((ing must be (o3 as it 3i(( be deposited at a (o3 temperature

X>o(idification must ta!e p(ace ,uic!(y if effectie hand(ing is to be achieed.

Enrobing:

The 3afer sheets to be coered 3ith choco(ate are p(aced on a coneyer band. =rom the

concaes band the centers are transferred to 3ire net 3hich first passes oer a bottom of

coating deice. This part of machine consists of a system of pumps or ro((ers 3hich produce a

sha((o3 surge of tempered choco(ate through the net4 (ifting the centers s(ight(y and at the

same time coating the bottoms. These bottom coated units are transferred automatica((y to

another be(t 3here the bottom choco(ate is coo(ed by passing oer a co(d tab(e and from this

to the main enrober net. The pre&bottomed centers are carried on this net through a curtain of

tempered choco(ate4 there by coating the sides and tops as 3e(( as proiding an additiona( thin

coating on the bottoms. After emerging from the curtain the coered choco(ates are subPected

to b(o3ing by air by fans and to ibration of the net. =rom the enrober net the choco(ates are

again transferred to a coneyer be(t 3hich ta!es them to the coo(er.

Packaging and Storage of Chocolate:

)ac!aging proides protection against hand(ing4 dirt4 taint and insect infestation as 3e((as moisture. And a(so it acts as a container and attracts the attention of the consumer. =or

++


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mou(ded choco(ate b(oc!s4 the bars are 3rapped by a(uminum foi( or O)) Soriented

po(ypropy(ene. Then the ones 3rapped 3ith a(uminum foi( are 3rapped again 3ith an

oer3rapper 3hich proide disp(ay appea( and carry the (ega((y re,uired product information.

E/UIPMENTS USED IN C&OCOLATE PROCESSMer+"

There are seera( systems to mi9ing one of them is Buh(er i9er. %n the Buh(er

i9er4 the input of ra3 materia(s and mi9ing process are automatica((y contro((ed. On the

other hand4 some ingredients (i!e a!yag cream4 soy f(our Snon&gmo4 (actose4 cinnamon and

po3dered ani((a are added by operators. The other adantage of Buh(er i9er is its

processing time. i9ing times are short4 $ to * minutes. And a ban! of mi9er is arranged to

hae a continuous f(o3 of paste to the refiners. The capacity of the Buh(er i9er is about *11

!g but the processed product in a hour by mi9er can change by the recipe of the production

p(an. The aim of the mi9ing is to get a homogenous choco(ate mi9. The mi9ing diagram is

sho3n be(o3

Re3er+"

The simp(est form of refining is by stone mi((s in 3hich the nib is graity&fed fromhoppers on the hori"onta((y positioned stone grinding 3hee(s4 often grooed to improe

>ugar i(! Cocoa po3der

Other ingredientsSe.g. po3dered ani((a4 cinnamon

MI'ER

)E&E=%NE 5 E=%NE>

Mixing diagram

+2

Cocoamass

Cocoabutter

Ha"e(nutpuree


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performance. The most 3ide(y used refining e,uipment is the $ or * ro((er mi((s. And I(!er

=actory uses refiners 3ith * ro((er mi((s.

Each ro((er operates at different speeds4 arranged to cause the choco(ate to f(o3 from the

(o3est ro(( ertica((y up3ards to the top ro((. The (o3est or feed ro(( is operated at the s(o3estspeed. Each ro(( is adPustab(e for spacing. The spacing bet3een the ro((s does not direct(y

re(ate to the si"e of partic(e produced particu(ar(y 3hen comparing different refinery

e,uipment. By the time the choco(ate is discharged from the top ro(( it is trae(ing eight to ten

times faster than it did on the feed ro((. o4 the

I(!er =actory uses 6 different conching machines. They are

C$: %ts capacity is appro9imate(y +4* tons. %t has t3o 3hee(s sett(ed one on the top

of the other. #uring the upper one turns right4 the other turns to the (eft. After a 3hi(e4 the

process is changed to the other side. =or this reason4 the best mi9ing is obtained by this

conching machine. i(!y choco(ate4 mi(!y mi9 are conched at here. Cocoa butter4 (ecithin and

)


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BR*: %t is the same machine as BR'. The t3o differences are

X %t is used on(y for mi(!y bar.

Xi9ing process ta!es 24*R$ hours.

THO-ET 657: The princip(e of the process is simi(ar to the BR' and BR* at these

machines. On(y4 there is one more 3hee( under the t3o 3hee(s. The capacity of them is $tons. Cocoa butter is added automatica((y and they are contro((ed by e(ectrica( contro( system.

They are used a(most for a(( !ind of choco(ates.

B-HLE CONCH: After choosing the recipe from the computer of this machine4

temperature4 e(ocity and turning of the 3hee(s are designated automatica((y.

%t is important to remind that

=EE#

+'


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i(!y choco(ates are conched at *1R71VC4

Bitter choco(ate is conched at 61R81VC.

Te5per36 Ma*43e+"

As the choco(ate is ready for discharge4 it is transferred to main storage tan!s and then

to minor storage tan!s from maPors in the case of production. The (i,uid choco(ate is sent to

temperer from minor storage tan!s Sa(so pass through a siee before entering temperer before

feeding the mou(ding or enrobing (ine. Tempering particu(ar(y determines the ,ua(ity of

choco(ate. Jou can adPust cocoa butter crysta( structure of choco(ate by temperers.

Types of tempering machines can be diided into t3o groups4 one is !ett(e temperingmachine and the other is continuous tempering machine:

Choco(ate @ett(e Tempering: %t is a hori"onta( machine being used in batch form. %t

can a(so be run continuous(y. @ett(es are easy to drain and c(ean. This is important if you are

producing different co(ors of choco(ate. A(so particu(ate ingredients such as nuts4 crysta(s of

sugar can be added at suitab(e points if the e9it pump is (o3 running. %t has a(so disadantages

that4 it needs a greater f(oor space than ertica( temperers and its start&up time is (onger than

the others.

aPor Continuous Tempering achines: Aested4 !reuter and so((ich are the e9amp(es

of these machines but at @aracabey factory4 Aasted4 3hich is 3or(d famous4 is being used. %t

has a stac! of configurab(e heat e9change p(ates scraped continuous(y to gie efficient coo(ing

and mi9ing. The choco(ate is pumped into the base of the machine and up3ards in a to&and&

fro moement through a(( p(ates and discharged at the top. There are capi((ary probes of the

contact thermometers p(aced at each coo(ing stage. hen the temperature set at the contact

thermometer has been reached4 the coo(ing 3ater is automatica((y (et in. The choco(ate (eaesthe temperer after being re&heated to the user temperature. This tempering machine is 3e((&

suited for mou(ding p(ants and enrobers and a(so it ta!es up minima( space.

M)7der+"

The (ine in 3hich definite&si"ed products are produced is the mou(ding (ine. A

mou(ding (ine genera((y contains mou(d heater4 depositors4 ibrators4 scrapers and coo(ers.

+*


16/34

MI'ING

REFINING

CONC&ING

A(so there is another mou(ding system ca((ed (oose mou(d system 3hich remoes the mou(ds

from (ine automatica((y for changing or c(eaning

E3r)er+"

An enrober consists of a drien 3ire rigid coneyor be(t on 3hich to transport the

3afer or other centers to be coated. This passes oer a stirred reseroir tan! 3hich ho(ds the

tempered choco(ate. A choco(ate pump circu(ates the choco(ate up a riser pipe and into the top

f(o3 pan. The f(o3 pan proides one or t3o curtains of choco(ate through 3hich the uncoated

centers pass. )(aced be(o3 the top f(o3 pan and beneath the grid is a bottoming through

Sca((ed as surge. This surge retains choco(ate fa((ing from the curtain and feeds it onto a f(at

p(ate4 thus forming a bed of choco(ate 3hich is moing 3ith the 3ire grid. The centers

entering the enrober are semi&suspended by this bed and become coated on the underside.After the choco(ate curtain4 an air no""(e is p(aced. By the adPustab(e b(o3ing air and

ibration of the net4 the amount of choco(ate remained on the center is adPusted. That is e9cess

choco(ate is remoed. Before entering the coo(er4 the center passes through an anti&tai(ing

deice 3hich ta!es off the drips of the choco(ate at the ends of the centers.

MATERIAL AND ENERGY %ALANCES

The ingredients added to mi9er are sent through some basic processes such as refiningand conching. #uring the refining process the diameter of the partic(es are reduced by using

force on the ingredients as ro((ers. After the refining process the mi9 is conched to hae a

homogenous mi9ture by adding (ecithin and a(so cocoa butter. Later the cocoa mi9ture is sent

to the tan!s by using pumps. hen needed4 choco(ate is ta!en from those tan!s to the

tempering machine to aoid mott(ed and mate surface. These processes can be sho3n as (i!e

that

Cocoa butter Uani((in

Cocoa mass i(! po3der

>ugar

Loss +

+6


17/34

Cocoa butter Lecithin

Loss 2 ater

)roduct ktan ater in ater out

Tempered Choco(ateSready for enrobing5mou(ding

Cp of mi(! choco(ate: 1.7* !P!g.@ Sat $1R$*VC4 Cp of 3ater: '.+87 !P!g.@ and Cp of p(astic

mou(d: +4$ !P!g.@

S!+e5 1" M36

Basis: One hour of operation

Assumptions: The (oss at mi9ing process is the 14+K of the choco(ate paste and the

choco(ate paste inc(udes 2'K of fat.

The (oss from the mi9ing process is assumed to be 14+K of the

product.

There is no (oss and addities in the composition of the choco(ate at

refining process.

The aim is to ea(uate the mass of the humidity of the product.

98%fat, 2%water Aroma MethylCocoa Butter Cb

40.4kg Vanlln V 0.!"kg

#ro$uct!, ) + kg

)

+ kg

""%fat,!%water

Cocoama&".0kgCm

'o!, L+ kg,0,!% of (ro$uct!

Mlk (ow$er 8!,) kg M(2%water

*ugar 2"0.0kg *!%water

+7

MIXING

TEMPERING


18/34

MlkButterMb+wthoutwater-".0kg

T)a7 Ma++ %a7a3*e" > Y b Y p Y Cm Y Cb Y UZ L + Y )+

2*1.1Y$*41Y8+46YY7*41Y'14'Y14+*Z L+ Y )+

'82.+* Z L + Y )+

'82.+* [1.++11Z L+ L+ Z14'82+*

'82.+*[//./+11 Z )+ ) + Z '8+467

& 2 O %a7a3*e" >[1.1+Yp[1.12YCm[1.1+YCb[1.12Z'8+467[H

2*1.1[1.1+Y8+46[1.12Y+8.$*[1.12Y7*41[1.1+Y'14'[1.12

Z'8+467[H

HZ+.+8K

S!+e5 2" C)3*436

Basis: One hour of operation

Assumptions: Lecithin is assumed to be +11K fat.

The product e9isting from the conch has +41K of 3ater.

%t is assumed that there is a (oss of (i,uid 3ater during the

process. And the (oss from the conching process is assumed to be

14'K of the its product.

'ecthn, 'h, !."" kg

) + , 48!,)&kg #ro$uct2, ) 2 !.!8%water,24,0%fat !.0%water, % fat

Cocoa butter, Cb 'o2,L 2 , 0,4% of the ) 2 2%water, 98%fat

+8

CONCHING


19/34

/ater, V, 2," kg

T)a7 Ma++ %a7a3*e" )+ YCb Y Lh ZUYL 2 Y ) 2

'8+467YCbY+.**Z24*Y ) 2 Y L 2

'81472YCbZ)2 Y) 2 [1.'+11Z) 2 [+.11' S+

T)a7 & 2 O %a7a3*e" )+ [+.+8+11YCb[2+11ZUYS) 2 YL 2 [++11

'8+467[141+8YCb[1.12Z24*Y+.11'[)2 [1.1+

Cb[1.12Y64+7Z1.1+[) 2

S2

By combining the e,uations of S+ and S2 3e are ab(e to get

CbZ14*[ ) 2

& $184*

CbZ ) 2

[+.11'R'81472

) 2

Z *2'47' !g of product2 and CbZ'64++ !g of cocoa butter

L 2 Z24+ !g is (ost during conching

S!+e5 8" Te5per36

Basis: +11!ghour of operation for choco(ate

Assumptions: The system of the tempering machine is adiabatic so that the

process is surrounded by iso(ated circumstances. There is no heat

entering and (eaing the system d0 and dE are assumed to be

"ero.

The !inetic and potentia( energy generated at the system are

neg(ected.

or! is gained by the stirrer is assumed to be "ero.

+/


20/34

ater entering the systemZater (eaing the system because

the percentage of 3ater in the choco(ate does not change during

the process.

#atum: 1.1+\C

As mentioned before

Cp of mi(! choco(ate: 1.8+ !P!g@ S at '1VC appro9imate(y.

Cp of mi(! choco(ate: 1.72 !P!g@ S at 28VC appro9imate(y.

Cp of 3ater: '.+87 !P!g@

Choco(ate in4 Ch in 4'*\C4

+11!gh

ater in4 in +1\C ater out4 out

+$\C

Choco(ate out4 Chout 428\C

H in H out

H in w4 1H in c4 H out w4 1H out c4

in [Cp w [ST inw4 &T d Y Ch in [Cp c [ST inc4 & T d Z

out [ Cp w [ST outw4 & T d YCh out [ Cp c [ST outc4 & T d

By p(ugging the data into the e,uation aboe4 S in Z out

['.+87[S+1R1.1+Y+11[1.8+[S'*R1.1+ Z ['.+87[S+$R1.1+Y+11[1.72[S28R1.1+

+628./+Z[+2.*6+

Z+2/46+ !gh is used during tempering the choco(ate.

/UALITY CONTROL TESTS

21

TEMPERING


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There are certain ,ua(ity contro( tests some of 3hich are done during production by

operators and some of 3hich are done by 0ua(ity Assurance #epartment. The ,ua(ity contro(

tests 3hich are done by operators are

+. fineness contro(4

2. iscosity contro(4

$. tempering contro( and

'. 3eight contro(.

The ,ua(ity contro( tests done by 0ua(ity Assurance #epartment are diided into '

group of (aboratories 3hich are e9p(ained in more detai(ed in appendi9 part are physica(4

microbio(ogica( and chemica( ana(ysis.

Pa*9a636 La)ra)r!:

A(( the ra3 materia(s and finished products are regu(ar(y tested by the emp(oyees 3ho

use a specia( test ca((ed obinson Test. And the other tests done are

>me(( Test

>trength and Outer Appearance Ana(ysis

M*r))7)6*a7 A3a7!++"

#etection and Enumeration of >taphy(ococcus Aureus

#etection and Enumeration of C(ostridium )erfringens

#etection and Enumeration of Baci((us Cereus

#etection and Enumeration of Co(iform

#etection and Enumeration of Tota( Bacteria

#etection and Enumeration of o(d and Jeast

C4e5*a7 A3a7!++ "

)H

Acidity

Ch(orides 5 NaC( )otentiometry Spotentiometric method

#etermination of Ascorbic Acid

=ree =atty Acid S==A #etermination

e(ting )oint #etermination

)artic(e >i"e #etermination S>ympatec too(

2+


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>ugar S)otterat&Eschmann method

Ash #etermination

Nitrogen #etermination

=at #etermination Sbuchi method

Humidity #etermination

ANALJ>%> #ONE ON CHOCOLATE A ATE%AL>

aw materal Chemcal A. Mcrobologcal A.

cocoa butter meltng range

ha3elnut(uree

aflaton B!,B!1B215!152,ah, l($

mlk l($ #ero$

mlk (ow$ermoture, l($,ac$ty

colform, totalbactera

cocoa l6ueur Moturecolform, totalbactera

Cocoa(ow$er

moture, l($,(7

colform, totalbactera, mol$,yeat

ethyl anlln meltng range

wafer flourmoture, ac$ty,(7, weght

colform, total

bactera, mol$,yeat

whey (ow$er Moturecolform, totalbactera

$ry gra(e Moture

colform, totalbactera, mol$,yeat

$ry ha3elnut

moture,afloton B!,B!1B215!152 colform

Almon$

moture,

afloton B!,B!1B215!15- colform

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ANALJ>%> #ONE %N CHE%>TJ LABOATOJ

)H ANALJ>%> #isso(e the samp(e in the disti((ed 3ater S++1

After ca(ibrating the pH&meter direct measurement is done

AC%#%TJ ANALJ>%>

>amp(e is disso(ed in boi(ed disti((ed 3ater

After coo(ing it is titrated 3ith 1.+ NaOH up to pH 7 by using a pH&meter

=EE =ATTJ AC%# S==A #ETE%NAT%ON

=ree fatty acid amount in fats is e9pressed 3ith o(eic acid percent.

The samp(e is disso(ed in ethano( diethy( ether mi9ture

Titrated 3ith @OH

ELT%N< )O%NT #ETE%NAT%ON

The me(ting point sho3s the degree 3here the fatty mass in the capi((ary tube starts to

go up.

)AT%CLE >%FE #ETE%NAT%ON

The choco(ate samp(e is disso(ed in egetab(e oi( Snear(y 1.2g

The >ympatec apparatus measures the partic(e si"es 3ith (aser beams in

microns in percents SK.

>-%>

=irst(y sugar is disso(ed in 3ater

=i(tered 3ith Carre" reagent

The CuS%% is reduced to CuS%

After the inersion CuO is disso(ed 3ith concentrated HNO$

2$


24/34

After then comp(e9sonometric Cu ana(ysis is done

A>H #ETE%NAT%ON

The 3eight of the residue4 corrected for the b(an!4 protein4 andAsh4 is e,ua( to the3eight of the tota( fiber.

The empty ash !ro"es are set to fi9ed 3eigh in the ash oen S**1VC

A !no3n amount of samp(e is 3eighed

The samp(e is burned in the oen unti( it becomes grey

Ca(cu(ated in percents SK

N%TO


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And its moisture is e9pressed as percentage

TA>TE4 >ELL AN# A))EANCE ANALJ>%>

A(( the finished products as 3e(( as the ha(f products are tasted4 sme((ed and theirappearance is contro((ed by the pane(ists in the factory before they are re(eased.

ANALJ>%> #ONE %N %COB%OLO


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abundant. %n addition to producing ethy( a(coho(4 the yeasts hydro(y"e the pectin that coers

the seeds. E9perimenta( fermentations indicate that S. cerevisiaedecreases the bitterness of

the fina( product. ithout pectin4 the bitter a(!a(oids may (each out of the seed or be a(tered

by a(coho( that can no3 enter the seeds.

. The yeasts are !i((ed by the a(coho( they produce and4 as the temperature rises4 (actic

acid bacteria such asLactobacillusand Streptococcusgro3. The pu(p is stirred and drained to

aerate it. The presence of o9ygen and the (o3er pH no3 faor the gro3th of acetic acid

bacteria4Acetobacterand Gluconobacter. After fie days4 the fermented mass contains up to

+18 microbes per gram. The beans are then dried and as they dry4 mo(ds inc(uding

E# %N THE =ACTOJ

Bactera Me$a:ncubaton tem(.+;C

:ncubaton tme+h

Coliform VB -0 24

Total bacteria #CA -0 &2

B.cereus M!8 2) "24

Coliform '*? -0 48

E.bacteria VB5 -& 24

Cl. Perfringens ?*C -& 24

S.aureus B# -& 48

UBZUio(et ed Bi(e Agar4 )CAZ)(ate Count Agar4 #TZLaury( Tryptose Broth4

UB


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ETHO#> ->E# TO #ETECT THE %COO%>

/a7! C)3r)7 ) M*r))7)6*a7 Te++" icrobio(ogists p(ay a ro(e in the ,ua(ity contro(

(ab of choco(ate manufacturers. They test materia(s and finished products for spoi(ageorganisms and pathogens. >tandard p(ate counts and tota( yeast and mo(d counts are

performed regu(ar(y. o(ds can spoi( choco(ate by hydro(y"ing (ipids. The resu(ting fatty

acids cause rancid tastes. Additiona((y4 choco(ate is tested for the fo((o3ing specific bacteria:

Staphylococcus aureus4 co(iforms4 and Salmonella. >eera( outbrea!s of sa(mone((osis hae

been traced to choco(ate that 3as contaminated after roasting. Current research is aimed at

dee(oping rapid methods such as EL%>A tests and #NA probes to detect Salmonella in

choco(ate. >a(mone((a tests are done in Nest(^ Ho((and Laborites because of its troub(esome

conditions. The s3ap rods are used to hand(e the samp(es4 then they are sent to the Ho((and

Laborites.

our late Method

+* m( me(ted agar is poured on to the + m( Smay change according to the enumeration

method di(uted samp(e.

A((o3ed to so(idify

)ut in to the incubator at desired temperature for desired time

Tota( bacteria4 Coli"orm# !nterobacteria# S.aureus# Cl. per"ringens are ana(y"ed by this

method.

Spread late Method

14+ m( samp(e is dropped on to the primari(y prepared agar

>pread 3ith the he(p of a g(ass spreader )ut in to the incubator at desired temperature for desired time

S.aureus# Cl. per"ringens# $.cereus4 and mo(d&yeast are ana(y"ed by this method.

$roth %ube Method

This method is used for certainty of the emp(oyed methods for detecting Coli"orm#

!nterobacteria# and S.aureus.

14+ m( samp(e is put into +1m( broth tubes )ut in to the incubator at desired temperature for desired time

27


28/34

)resence of gas is detected

Brain Heart %nfusion agar for S.aureus Sdetection of the turbidity is done4 not the gas e9it

during the usage of this agar4 T for Coli"orm

ana(ysis are used.Dee*)3 ) +)5e 5*r))r6a3+5+" >ome of the characteristics of the microorganisms are

gien be(o34 for detecting them during the mentioned methods

Co(iform: presence of gas in the durham tubes.

B.cereus: Beige 3ith round shape centre and surrounded 3ith a 3hite "one.

E.bacteria: )urp(e4 round and smooth co(onies.

>.aureus: B(ac!4 round and shiny co(onies surrounded 3ith a c(ear "one.

C(. perfringens: B(ac!4 round shaped co(onies.

CO>T ANALJ>%>

The most important and crucia( part of determining the profit of a defined product is

cost ana(ysis and other production cost.The production cost is the money that shou(d be paidfor different items in order to obtain the fina( product after certain app(ication. These itemsare as fo((o3ing

ateria( cost: The maPor component of these items is materia( cost 3hich inc(udes thera3 materia(s necessary for the product and pac!aging materia(s. This item a(most constitutes6*K of the tota( cost.

)ac!aging cost: There are a (ot of pac!aging materia(s used such as for mou(dedchoco(ate4 a(uminum foi(4 paper 3rappers4 outers4 cases and for sea(ing g(ue or tape.

Labor cost: %t is needed 3or!ers for production so (abor cost is the ne9t important item.This item inc(udes (abor4 do3ntime (abor and other indirect (abor Smay be security and peop(e3or!ing in different areas. %nsurance may be inc(uded in this group.

#epreciation: There are a (ot of machines 3or!ing most(y fu(( time4 they undergodepreciation in the other 3ords their physica( faci(ities deteriorate and usefu(ness of themdecreases.

Energy and (aboratory cost: most of the machines run on e(ectricity4 it is a(so importantbut 3hen compared 3ith other items 4it a(most constitute (ess than *K of the tota( cost.

28


29/34

=i9ed cost: The fi9ed costs change (itt(e or not a(( 3ith the amount of production.These inc(ude costs for (oca( property ta9es4 sa(aries4 insurance4 energy consumption infactory e9cept production4 etc

As it is mentioned at the beginning4 the cost ana(ysis is the crucia( part for determining

the profit of a defined product so nobody 3ants to gie the cost of his product. >ince they are

a(3ays in a competition 3ith their competitors in the mar!et. Because of these reasons and

another reason that % 3as in production department4 not department of accountancy during my

summer practice4 so that % cou(d not find enough data

CONCLUSION

Especia((y the summer practice that % comp(ete in Erg;n in this summer has he(ped

me to (oe my Pob.. %t 3as taught me so much about 3or!ing (ife. it 3as a great adenture at

first4 but at the end it turned to be a great e9perience. % hae eer seen big machine and ery

big manifuctured.

The most important thing that p(eased me 3as to see that they rea((y attach importanceto peop(e4 they do not gie responsibi(ities to trainee but they rea((y 3anted me to (earn

something. And a(so it is ery hard to (earn specia( point of production of choco(ate.

As a conc(usion4 % am ery p(eased haing done my summer practice in Erg;n.% be(iee that

my summer practice in Erg;n 3i(( be an important and good reference for my future career

APPENDI'

TJ)%CAL CHOCOLATE =O-LAT%ON>

TJ)%CAL )ECENTAugar '8.7 '8.+ $6.$

2/


30/34

=(aor compoundsSe.g.4 sa(t and

ani((in1.+ 1.+ 1.2

ho(e mi(! po3der +/.+

Tota( fats$+.* $6.' $*.'

A )icture of Cacao )ods

$1


31/34

>hematica(y #iagram of from cocoa beans to choco(ate and cocoa po3der and

cocoa butter

A )icture of efiner

$+


32/34

A )icture of i9er achine

A )icture of Temper achine

$2


33/34

REFERENCES

+& Cocoa4 Choco(ate and e(ated )roducts4 >ugar Confectionary and Choco(ate anufacture4 Lees .

and Wac!son B.B.4 Chemica( )ub(ishing Co. %nc.4 +/7*

2&i(! and i(! )roducts4 >ugar Confectionary and Choco(ate anufacture4 Lees . and Wac!son

B.B.4 Chemica( )ub(ishing Co. %nc.4 +/7*

$&icrobio(ogy and is! Assessment of Cocoa %ngredients and Choco(ate4 a"igh #.-nite d]Eco(ogie Bacterienne4 +/8$.

'&Temperers4 enrobers4 mou(ding e,uipment and coo(ers4 %ndustria( Choco(ate anufacture and -se4Ne(son .B.4edited by Bec!ett >. #.4 B(ac!3e(( >cience4 O9ford4 +///

*& ateria( and energy ba(ances in food engineering4 Esin A(i4 ET- )ress4 +//$

6&The ateria( >cience of Choco(ate4 )eter =ryer and @erstin )inscho3er4 >Bu((etin #ecember21114 from 333.mrs.orgpub(icationsbu((etin

$$


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Documents

ERG+£N CHOCOLATE