Process Technology


Useful tips for working with chocolate
The following temperatures are given as an example

Storing Chocolate Chocolate is susceptible to moisture and absorbs external odors. Store chocolate in a cool, dry place away from light and air. The ideal temperature for storing chocolate is between 54 and 68 F (12 and 20 C).
Melting Chocolate Chocolate melts best at temperatures between 104 and 113 F (40 and 45 C). Never melt chocolate directly over a heat source. Use indirect heat such as a hot water bath so that the chocolate reaches a uniform temperature of 104 to 113 F. This is the perfect temperature to begin tempering or precrystallization.
Tempering or Precrystallization Tempering is of paramount importance as it is mainly responsible for determining the final gloss, hardness, and contraction of the chocolate. Tempering consists of heating the chocolate to a specific temperature as a result of which the cocoa butter it contains is brought to the most stable crystalline form resulting in hard, shiny chocolate.
Tempering by hand Melt the chocolate over a hot water bath until it reaches a temperature between 88 and 90 F (31 to 34 C). Melt white and milk chocolate to a temperature approximately 2 F less, depending on the amount of milk fat they contain.

On a cold table or marble surface:
Pour 2/3 of the melted chocolate onto the cold table.

Spread out the chocolate mass and work with a spatula until the temperature of the chocolate is approximately 81 F (27 C).

Add the tempered chocolate to the non-tempered chocolate and mix thoroughly until the mass in the bowl has a completely uniform.

Temperature:
If the temperature is still too high, part of the chocolate should be further worked on the cold table until the correct temperature is reached. 

Tempering by seeding Tempering can also be carried out by adding stable crystals to the melted chocolate. Callebaut manufactures chocolate in a convenient small, round particles for this process. This chocolate is known as CALETS. The quantity of Calets to be added depends on the temperature of the melted chocolate and on the temperature of the Calets. The Calets should generally be used at room temperature.
Tempering by machine The melted chocolate at a temperature of approximately 104 F (40 C) is poured into the machine which then takes care of the rest of the correct tempering process.
Checking Tempering A simple method of checking tempering is by applying a small quantity of chocolate to a piece of paper or to the point of a knife. If the chocolate has been correctly tempered it will harden evenly and show a good gloss within five minutes.
Temperature of the Workshop, of candied to be coated, of molds The ideal temperature of the workshop should be approximately 68 F (20 C). 

The temperature of the candies and fillings to be coated should be as close as possible to the temperature of the coating chocolate. If the temperature of the candies or filling varies too much from that of the chocolate, the crystallization of the cocoa butter will be adversely affected. This will result in a product which is dull and is less resistant to heat. 

The temperature of the molds should be as close as possible to that of the workshop without being less, approximately 68 F (20 C). If necessary, the molds can be warmed slightly. Take care that the temperature of the molds does not exceed that of the tempered chocolate. Using molds that are at the proper temperature will result in the best possible gloss for the finished product. 

*Important note: During use, the tempered chocolate in the bowl may thicken further. This is the result of the rapid growth in the size of the cocoa butter crystals. This thickening of the chocolate can be prevented by adding a small quantity of warm chocolate or by increasing the temperature of the chocolate slightly. 

Cooling the Chocolate For molded products, the best temperature to cool chocolate is 50 to 54 F (10 to 12 C). When cooling molded products, a large circulation of air is necessary as a large quantity of heat must be removed when the chocolate is solidifying. When molded products are ready to be cooled they should be placed in an area which is cooler than the workshop. This will give the first hardening to the chocolate. They should then be placed in the refrigerator or chilling area. 

fillings, the best temperature to cool chocolate is 59 to 64 F (15 to 18 C). Enrobed products are best cooled with radiation cooling ( withou convaction ).see the diagram in our catalog . 

It is important to avoid changes in temperature in excess of 50 F (10 C). 

Storage of Finished Products As with raw chocolate, the finished product is also susceptible to temperature, external odors and flavorings, air and light, moisture, and time. It is important that the finished products are preserved in ideal conditions. Only perfect storage will guarantee the original chocolate properties and will avoid decay or undesired features.
Typical problems affecting chocolate products during storage are Fatbloom- When a thin layer of fat crystals forms on the surface of the chocolate. This will cause the chocolate to lose its gloss and a soft white layer will appear, giving the finished article an unappetizing look. Fatbloom is caused by the recrystallization of the fats and/or a migration of a filling fat to the chocolate layer. Storage at a constant temperature will delay the appearance of fatbloom. 

Sugarbloom- This is a rough and irregular layer on top of the chocolate. Sugarbloom is caused by condensation (when the chocolate is taken out of the refrigerator). This moisture will dissolve the sugar in the chocolate. When the water evaporates afterwards, the sugar recrystallizes into rough, irregular crystals on the surface. This gives the chocolate an unpleasant look. You can prevent sugarbloom by preventing temperature shocks. When chocolate comes out of a cold room, it should be stored in a warm area long enough before opening the package to keep direct condensation from forming. 




Other Influence
The following factors should be taken into account

  • Time
    The shorter the period of storage, the better the quality of the product. Use the first in/first out system to ensure that products that arrived first are dispatched first. In this way, products are stored for as short a time as possible. Consequently, optimal freshness is guaranteed.
  • Temperature
    The ideal storage temperature for chocolate is between 54 and 68 F (12 and 20 C). At higher temperatures, the chocolate will soften and will lose its gloss. Lower storage temperatures are less risky. When products are brought to room temperature, condensation should be avoided, otherwise sugarbloom will arise. Fluctuating temperatures should also be avoided, because they will accelerate the appearance of fatbloom.
  • Environment
    Chocolate is very sensitive towards odors. That is one of the reasons why chocolate should be stored in a place free of stuffy or strange odors and with a good air flow. Chocolate should not be stored next to or between strong-smelling products. The packaging of chocolate products needs to be fully neutral. This means that the material may not give off any odor.
  • Light and Air
    Under the influence of light and air, chocolate will oxidate more quickly and deteriorate in taste. Therefore, it is very important to protect the chocolate from light and air as much as possible by storing it in closed packaging. Dark and milk chocolate naturally contain anti-oxidentia (these are agents that slow down the oxidation process). White chocolate does not contain these substances. That is the reason why white chocolate is much more sensitive towards oxidation than dark or milk chocolate. White chocolate should be better protected.
  • Humidity
    Chocolate should be protected against humidity. Chocolate should be stored in an area where the maximum relative humidity is 70%. Do not pile chocolate products directly on the floor or in direct contact with the walls, because in this case the chance of moisture absorption increases strongly.



  • Possible Difficulties


    The Problem Origin Remedy
    Difficulty unmolding The coating was incorrectly tempered

    The coating was too thin

    The cooling temperature was too high
    See tempering

    use a less liquid coating

    See cooling
    Whitening or greying of chocolate The coating was incorrectly tempered

    The coating solidifies too slowly

    Overcrystallized chocolate
    See tempering

    See cooling

    See tempering
    Cracking when molding The refrigerator was too cold

    The coating was too thin and cooled too quickly
    See cooling

    See cooling
    Dull stains on molded candies The molds were too cold See temperature of molds
    Thickening of coating while working Excessive crystallization in the chocolate Increase the temperature slightly

    Add a small quantity of warmer chocolate

    Do not add extra cocoa butter
    No gloss following enrobing The filling was too cold

    The workshop was too cold

    The coating was not tempered
    See temperature of fillings

    See temperature of workshop

    See tempering
    Fingerprints on finished products The product has been touched with warm or moist fingers Make sure hands are dry

    Use gloves when necessary
     


    MF-Hamburg