Ideal Raw Material Versatile Consistent Quality 7 Economical_~ pecialty fats include cocoa butter equivalent (CBE), cocoa butter substitute (CBS), general purpose coating fats and toffee fat. Palm oil and palm kernel oil are ideal raw materials for the production of specialty fats due to their excellent physico-chemical properties. They can be further modified to extend their range of utilization. CBE are specialty fats which contain symmetrical unsaturated triacylglycerols similar to that of cocoa butter (Table 1). CBE are often regarded as fully compatible to cocoa butter. Generally, CBE is formulated with palm mid fraction (PMF) blended with illipe and shea fats. CBS are classified as lauric and non-lauric based. Lauric CBS are derived from the two major lauric oils namely palm kernel oil and coconut oil. Palm kernel oil can be fractionated to give palm Kernel stearin with similar physical properties to cocoa butter. The stearin, with or without hydrogenation, is an excellent CBS suitable for the manufacture of solid or hollow-molded chocolate products. Palm Based Chocolate Products Non-lauric CBS are made from oils such as palm, soyabean, cottonseed and peanut oils. They have to be hydrogenated in order to bring their consistency to appropriate levels. These products have excellent uses in compound coating for biscuits, enrobed products and chocolate flavoured baking chips. In products where price consideration is important, this type of CBS is a good alternative. INGREDIENTS PROCESSING Plain chocolate contains sugar, cocoa mass, 10% cocoa butter The ingredients are premixed. Melted fat is added and mixed and 5% CBE. Milk chocolate contains sugar, full cream milk until smooth. It is then refined, canched, tempered, moulded, powder, cocoa mass, 15% cocoa butter and5% CBE. Inchocolate cooled and demoulded. The chocolates are then stabilised to pastel, the cocoa is omitted completely. The colour of chocolate complete crystallization. pastel i basicaly white and colour can be added tomakeit more attractive PROCESSING STEPS Refining Itis important to refine chocolate paste in order to obtain the required smoothness. The mass is ground until 80% of particle size distribution is between 20- 30, A roll refiner is commonly used for this purpose. 1 Premixing Raw materials i.e. cocoa liquor, sugar and milk powder are mixed with an adjusted fat content (26 + 1%| before the mass is refinedChocolates give people great pleasure while eating. It also makes a suitable gift for many occassions. The fat content of chocolate varies from 28% to 35% depending on its intended use. Cocoa butter obtained from cocoa beans or specialty fats obtained from vegetable oils and fats are the usual sources of fats for chocolate manufacture Conching This process is characterized by chemical and physical change in the product mix. CChocolaty flavour develops during the process and water content i reduced to less than 1%. A homogenous product mass is produced in an efficent homogeniser and this is @ crucial step. During conching good temperature control is also essential. Temperature for plain chocolate is 65 - 80°C and for milk chocolate 50 - 65°C. Time for conching depends ‘on the composition ofthe mass but itis normally more than 3 hrs and often longer for plain chocolate Tempering Tempering of the chocolate mass based on CBS is caried aut by heating the mass at 60- 60°C and coolingitto at least 2°C above the quoted sip point af the ft. For CBE based chocolate it isnecessary ta form the right amount of stable crystal inthe chocolate mass to enable moulding ‘The mass is heated at 50 - 60°C and cooled te 26.5 - 27.5°C for plain chocolate and 25.5 - 26.5°C for milk chocolate. Moulding Temperature of the mass is raised to 31 - 33°C (plain chocolate) and 29 - 31°C (milk chocolate) respectively before moulding. Temperature of the mould should be 2 - 5°C lower than the moulding temperature ofthe mass, The chocolate mass is filled into the mould, tapped and excess chocolate is scrapped off. The chocolate is then cooled ina cooling cabinet set at 5 - 12°C,Advantages of Using Palm Based Fats in Chocolate Products * Does not require tempering Chocolate based on CBS crystallize rapidly into stable pv crystal form, thus there is no need for tempering. This saves processing time. * Forms stable crystals and are less subject to bloom Chocolate made with CBS has @ good resistance to fat bloom, thus the product looks shiny and attractive © Have rheological properties suitable for modern, highly flexible production lines The same production plant used for pure cocoa butter chocolate can be used * Stable in hot climates The melting properties ofthe fats higher than the melting properties of cocoa butter due to the stearc-oleic-stearie (St0St triglyceride content. [tis more stable in hot climates than cocoa butter Cooling and demoulding AA suitable cooling cabinet with air circulation and sufficient cooling capacity should be used. Cooling temperature is usually between - 12°C and time should ‘ot exceed 45 mins (normally 15 ~ 20 min). For easy ddemoulding the shrinkage should be sufficient, Dificult ddemoulding may be caused by + mould not sufficiently cleaned = chocolate not properly tempered temperature of the mould not appropriate 7 Stabilisation The finished products are stabilised at 18°C - 20°C for at least 24 hrs to complete crystallisation. Consistent quality CBS has a low iodine value, indicating low levels of unsaturated fatty acids. Thus they are stable against oxidative deterioration. Reliable supply Palm oil and palm kernel oil can be obtained all the year round. The oils are readily available to be processed for CBE and CBS production. Versatile The fats are bland in flavour. They can be used for chocolate flavoured end products and white compounds and pastels. The fats are also compatible to @ certain degree with mikfat and other non-aurc ails Economical ‘The price ofthese fats are cheaper than the price of cocoa butter.Costs canbe reduced by replacing partof the cocoa butter with CBE or by replacing the total amount of cocoa butter with CBS.Plain and milk chocolate formulation using CBE 25% full cream milk powder 15% CB SeCBE | «| SH CBE 45% sugar | 45% suger 30% CBS 40% icing sugar 46% icing suger 20% skim milk powder Chocolate Process Flow Chart RAW MATERIALS PREMIXING Mix chocolate liquor, sugar and milk powder and adjust fat content to-26% REFINING Grind and smoothen chocolate mass to 20 - 30 size. CONCHING © Mixture is homogenised © Water content reduced to <1% © Mixis conched for 3-36 hours at controlled temperature ~ Plain chocolate 65 - 90°C - Milk chocolate 50 - 65°C + TEMPERING ces: * Cool chocolate mass to 2- 5° above melting point ofthe fat. Tampering is not required for it can be moulded immediately, CBE: * Cool chocolate mass : i. Plain Chocolate + 265-275°C ii, Milk Chocolate + 255-265°C ‘© Raise temperature of chocolate mass before moulding: Plain Chocolate —» 31-33°C Milk Chocolate + 29- 31°C MOULDING © Mould temperature is 2 - 5°C lower than moulding temperature of chocolate mass + COOLING Cool at § 12°C for 16-20 min. STABILISATION 18- 20°C for 24 hours to complete crystallization | sos) Reference | Nor Aini and Sabariah, §. 1995. Development of 25 | Specialty Fats for Sefected Food. Paper Presented at National Seminar on Food Technology ‘95 "Food Table 1. Triacyglycerol composition of CBE and cocoa butter | Pop | Pos 30 2 | Cocoa butter (Malaysia) 15, 35 2 Ingredients” §-7 Sot, Kua Lumpur P = palmitic acid