Cocoa, Chocolate and Ice Cream are the products which has a good nutritious value and relatively inexpensive food. Cocoa butter is used in chocolate and to cover other confectionery products. Now a day chocolate and ice cream are gaining good popularity among the society all over the world. Chocolate is a key ingredient in many foods such as milk shakes, candy bars, ice creams etc. It is ranked as one of the most favorite flavors in the world. Despite its popularity, most people do not know the unique origins of this popular treat. Chocolate is a product that requires complex procedures to produce. The process involves harvesting coca, refining coca to cocoa beans, and shipping the cocoa beans to the manufacturing factory for cleaning, coaching and grinding. These cocoa beans will then be imported or exported to other countries and be transformed into different type of chocolate products. Ice cream is a frozen dessert usually made from dairy products, such as milk and cream, and often combined with fruits or other ingredients and flavors. The meaning of ice cream varies from one country to another like frozen custard, frozen yogurt, sorbet, and gelato and so on. The ice cream industry has traditionally grown at a healthy rate of 12% per annum. India is the second largest milk producing country. Milk products like butter, curd, ghee, etc have become an essential part of our food and are consumed in good quantity every day. In spite of the huge demand that exists for such milk based items conventional methods are employed for producing these items. The growth in cocoa, chocolate, Ice cream and other milk product industry has been primarily due to strengthening of distribution network and cold chain infrastructure.
Some of the fundamentals of the book are cocoa bean production, sources of cocoa bean supplies, refining for production of chocolate masses for different uses, shipment of cocoa beans, cocoa processes , cocoa for drinking, instant cocoas, drinking chocolates manufacturing cocoa, cocoa butter & replacement fats , coatings and cocoa , chocolate manufacture, chocolate bars and covered confectionery , chocolate molding, determination of fat in cocoa and chocolate products, determination of cooling curve of cocoa butter and similar fats, the manufacture of dairy products, ice cream manufacture, energy value and nutrients of ice cream etc.
The present book contain formulae, processes and other relevant details related to manufacture of cocoa products, chocolates, ice cream and other milk products. An attempt has been made to bring in to focus the significant aspect of cocoa products, dairy products manufacturing. It is hoped that the subject matter contain and its presentation will be very helpful to new entrepreneurs, professionals, institutions, technocrats and students etc.
1. COCOA BEAN PRODUCTION
Introduction
Botanical types
The preparation of cocoa beans
Fermentation
Drying
The cut test
Sources of cocoa bean supplies
Shipment of cocoa beans
Infestation of cocoa
Microbiology of cocoa
2. COCOA MASS, COCOA POWDER, COCOA BUTTER
Introduction
Cocoa mass
Cocoa powder
Cocoa butter
Quality control
3. PARTICLE SIZE REDUCTION
Introduction
Current types of particle size reduction process
Grinding cocoa nib into cocoa mass
Refining of chocolate masses
The roll refiner
Refining for production of chocolate masses for
different uses
4. COCOA PROCESSES
RawBean Cleaning
Roasting
The NARS Process
Micronizer
Roasting of Nib
Sterilization
Alkalization
Cocoa Liquor Treatment
Winnowing(Cracking & Fanning)
Winnowing Machines
Large nib:
Small nib:
Nib dust (fine nib)
Shell dust, small shell, cyclone dust
Large shell
NIB GRINDING, COCOA LIQUOR, HEAT TREATMENT
Ball or Bead Mills
PROCESSING OF COCOA LIQUOR
Flavour Development Processes
(The following is a summary of the methods used.)
Simple Heating of Thin Films
ThinFilm Roasting and Air Scrubbing
ThinFilm Roasting with Vacuum
General Comments
ALKALIZATION
Alkalization of Nibs
Alkalization of Liquor
Drying, Roasting, Pressing, and Grinding
Alkalization of Cocoa Cake
Alkalization of Whole Beans
Water Treatment
LIQUOR PRESSING
Temperature of the Liquor
Moisture Content
Degree of Roast/Protein Coagulation
Homogenizing
Particle Size
Pressures
EXPELLER PRESSING
COCOA GRINDING
Cocoa Fineness
COCOA FOR DRINKING, INSTANT COCOAS, DRINKING CHOCOLATES MANUFACTURING COCOA
Drinking Cocoa
Instant Cocoa
Drinking Chocolate
COCOA POWDER MICROBIOLOGY, COMPOSITION, ANALYSIS
Cocoa Composition and Specifications
Contamination and Adulteration of Cocoa Powder
5. Cocoa Butter & Replacement Fats
COCOA BUTTER
Prime Pressed Cocoa Butter
ExpellerPressed Cocoa Butter
SolventExtracted Cocoa Butter
Constitution of Cocoa Butter
Properties of Cocoa Butter
New Sources of Supply Natural Variations
Supercooling, Cooling Curves
Crystallization, Polymorphism
Hardness, Penetration
Contraction
Solvent Extraction of Cocoa Butter
Refining of SolventExtracted Fat
Deodorization of Cocoa Butter
COCOABUTTER REPLACEMENT FATS
Equivalent Fats (CBE)
Substitute Fats (CBS)
Other Fats Associated with Cocoa Butter
Allied Fats
6. EMULSIFIERS IN CHOCOLATE CONFECTIONERY
7. COATINGS AND COCOA
VEGETABLE LECITHINS
Soya Lecithin
Other Vegetable Lecithins
Fractionated and Modified Vegetable Lecithins
USE OF VEGETABLE LECITHIN AND OTHER PHOSPHOLIPIDS IN CHOCOLATE
SYNTHETIC PHOSPHOLIPIDS AND MODIFIED VEGETABLE LECITHINS
Toxicity Checks on YN
Viscosity
Other Physical Effects of Lecithin Addition
Other Surface Active Compounds
RHEOLOGY, VISCOSITY, DEFINITIONS, MEASUREMENT OF VISCOSITY
VISCOMETERS
Simple Viscometers
Rotational Viscometers
The Gardner Mobilometer
USE OF LECITHIN IN CHOCOLATE, COCOA POWDER, CHOCOLATE DRINKS
Chocolate
Cocoa and Drinking Chocolate Powders
8. CHOCOLATE MANUFACTURE
INGREDIENTS
Sugar and Other Sweeteners
Cocoa Butter
Milk Products
Emulsifiers
Other Fats
FLAVOUR
REWORK
CHOCOLATE PROCESSES
Preparation of Ingredients
Mixing
Refining
Milk Chocolate Processes
Conching
Other Conches and Chocolate Making Systems
Viscosity of Chocolate
8. CHOCOLATE BARS AND COVERED CONFECTIONERY
PRODUCTION METHODS
Molding
Enrobing
Panning
Tempering
OTHER CHOCOLATE PROCESSES
Chocolate Drops (Chips)
Roller Depositing
Aerated Chocolate
Chocolate Flake or Bark
Chocolate Vermicelli or Streusel
Laminated Chocolate
Chocolate Tempering
Compound Coatings
Measurement of Degree of Temper
CHOCOLATE MOLDING
Molding Chocolate Blocks or Bars
Hollow Goods
Foiled Articles
Shell Forming Equipment
The Westal SCB Process
COMPOSITION OF CHOCOLATE FOR MOLDING
MOLDING AND SHELL PLANT COOLERS
Tablets
Shells
GOOD MANUFACTURING PRACTICE
CHOCOLATE ENROBING
Mechanical
Chocolate Cooling
Enrober Coolers
Automatic Enrober Systems
Chocolate Enrobing Problems
Zein Glazes
9. QUALITY CONTROL
Who Decides the Standard of Quality?
Who Controls Quality?
How Should Quality Control Be Organized?
RAW MATERIALS
Type of Raw Material
The Supplier
PROCESS CONTROL
InLine Process Control
FINISHED PRODUCT INSPECTION
Appearance
Incidence of Sampling Taste Checks
Weight Control
Shelf Life Keeping Limits and Keeping Tests
Microbiological Quality Control
Food poisoning
Factory Hygiene and Sanitation
Prevention of Foreign Matter Contamination
Travel Tests
10. SPECIAL METHODS OF ANALYSIS
PARTICLESIZE DETERMINATION
Methods of Determination
Micrometer
Metriscope
Method of Determination
Microscopes
Sieving Methods for Determining Particle Size
Elutriation (Sedimentation) Methods
Particle Sizing by Laser Beam
The Coulter Counter
DETERMINATION OF FAT IN COCOA AND CHOCOLATE PRODUCTS
Rapid Methods using Trichlorethylene Extraction
Refractometer Methods
Determination of Fat Using Nuclear Magnetic Resonance
Determination of Cooling Curve of Cocoa Butter and Similar Fats
Method Apparatus
Procedure
The Melting Point of Fats
Determination of Fusion, Slip and Clear points
Determination
Softening Point of Fats
Barnicoat Method
Hardness of Fats
Foam Test Modified Bickerman Method
WATER ACTIVITY, EQUILIBRIUM
RELATIVE HUMIDITY
Determination of A/W
Calculation of A/W/ERH
Determining A/W Using Solutions of Salts
A/W Determination by Protimeter
SCIENTIFIC INSTRUMENTS EMPLOYED IN PRODUCTION DEPARTMENTS
Viscometers
Refractometers
1. Traditional Method
2. Standardized Method
SWEETENED DAHI
Market Quality
Packaging and Storage
Keeping Quality
Increasing Keeping Quality
Dahi Powder
1. Whole Milk Dahi
2. Skimmed Milk Dahi
11. THE MANUFACTURE OF DAIRY PRODUCTS
Butter
CHURNING
CHEESE
THE MANUFACTURE OF HARD CHEESE
SOFT CHEESE
12. TECHNOLOGY OF KHOA MANUFACTURE AND STORAGE
EFINITION
KHOA A REMUNERATIVE PRODUCT WITH SIMPLE TECHNOLOGY
VARIETIES AND GRADES OF KHOA
1. Pindi
2. Dhap
3. Danedar
CHEMICAL COMPOSITION OF KHOA
MICROBIOLOGICAL QUALITY OF KHOA
EXISTING TRADE PRACTICES
METHODS OF MANUFACTURE
SMALL SCALE PREPARATION OF KHOA
1. Equipment
2. Quality of Milk
3. Traditional Process
IMPROVED BATCH METHOD FOR KHOA PREPARATION
PACKAGING AND STORAGE OF KHOA
LEGAL ASPECT OF KHOA MANUFACTURE
13. TECHNOLOGY OF MANUFACTURE OF YOGHURT AND DAHI
YOGHURT
2. Details of Manufacture
METHOD OF PREPARATION OF FLAVOURED YOGHURT
CURD (DAHI)
DEFINITION
CLASSIFICATION
FOOD AND NUTRITIVE VALUE
COMPOSITION
USES OF DAHI
SWEET SOUR DAHI
1. Traditional Method
2. Standardized Method
SWEETENED DAHI
Market Quality
Packaging and Storage
Keeping Quality
Increasing Keeping Quality
Dahi Powder
1. Whole Milk Dahi
2. Skimmed Milk Dahi
14. FLAVOUR DEVELOPMENT IN CHOCOLATE
Introduction
Fermentation
Drying
Roasting
Conching
Conclusion
15. ICE CREAM
16. ENERGY VALUE AND NUTRIENTS OF ICE CREAM
ENERGY VALUE AND NUTRIENTS
CALORIC CONTENT OF ICE CREAM AND RELATED PRODUCTS
PROTEIN CONTENT OF ICE CREAM
MILKFAT CONTENT
CARBOHYDRATES IN ICE CREAM
MINERALS IN ICE CREAM
VITAMINS IN ICE CREAM
PALATABILITY AND DIGESTIBILITY
OF ICE CREAM
17. ICE CREAM INGREDIENTS
OPTIONAL INGREDIENTS
COMPOSITION OF MILK
MILK PRODUCTS USED IN ICE CREAM
Sources of Fat
Skim Milk and Buttermilk, Liquid and Dry
Dry Whole Milk
Concentrated Milks
Special Commercial Products
Mineral Salts
SWEETENERS
Relative Sweetness
Effect of Sweeteners on Freezing Point
Sucrose
Corn Sweeteners and Related Ingredients
Maple and Brown Sugars
Honey
Nonnutritive Sweeteners
Fat Replacers
Sugar Alcohols
Syrups
18. STABILIZERS AND EMULSIFIERS
USES OF STABILIZERS
KINDS OF STABILIZERS
CHARACTERISTICS OF INDIVIDUAL STABILIZER INGREDIENTS
ICE CREAM IMPROVERS
EMULSIFIERS
INDUSTRIAL USAGE
19. FLAVOURING AND COLORING MATERIALS
FLAVOURS FOR FROZEN DESSERTS
VANILLA
Imitation Vanilla Flavourings
Consistency in Vanilla Quality
Vanilla Ice Cream
CHOCOLATE AND COCOA
Processing Cocoa Beans
Characteristics of Cocoa
Chocolate Ice Cream
Preparing Chocolate Syrup
Freezing Characteristics
Chocolate Confections
FRUITS IN FROZEN DESSERTS
Fresh Fruit
Candied and Glaced Fruits
Dried Fruits
PROCEDURES AND RECIPES
Strawberry Ice Cream
Raspberry Ice Cream
Peach Ice Cream
Cherry Ice Cream
Ice Cream with Complex Flavours
Sugar Free
NUTS
SPICES AND SALT
COLOR IN FROZEN DESSERTS
FLAVOURING LOWFAT AND NONFAT ICE CREAM
20. MIX PROCESSING
PREPARATION OF THE MIX
Combining the Ingredients
PASTEURIZATION OF THE MIX
HOMOGENIZATION
AGING MIXES
PACKAGING MIXES FOR SALE
FLAVOURING MIXES
21. THE FREEZING PROCESS
PREFREEZING TESTS
FREEZING OPERATIONS
CHANGES THAT TAKE PLACE DURING THE FREEZING PROCESS
REFRIGERATION NEEDED TO FREEZE ICE CREAM
CALCULATING REFRIGERATION REQUIREMENTS
TYPES OF FREEZERS
The Continuous Freezer
The Refrigeration System
Advanced Programmable Freezers
Shut Down and Cleaning of the Freezer
The Batch Freezer
Operation of the Batch Freezer
Filling Containers from a Batch Freezer
22. FANCY MOLDED ICE CREAMS, NOVELTIES, AND SPECIALS
PRODUCTION SYSTEMS
^ Top
