Chocolate Production

Prepared by: Supervisor:

Ali Mohammed S. A. Aqlan
Ibu. Dr. Ririh
101914353014
MASTER OF ENVIRONMENT UNAIR
PHUA-INDONESIA
 Manufacturing Company

American Company Mars.

Mars, Incorporated is an American global
manufacturer of confectionery, pet food,
and other food products and a provider
of animal care services, with US$33 billion
in annual sales in 2015. It was ranked as the
6th largest privately held company in the
United States.

Snickers Chocolate Bar

Snickers is a brand name chocolate bar made by the American company Mars, Incorporated,
consisting of nougat topped with caramel and peanuts that has been enrobed in milk chocolate.
 The Main Components of Snickers
Chocolate Bar

Fig.1 Components of Snickers Chocolate Bar

Fig.2 Components Percent in Snickers Chocolate Bar

 Chocolate Manufacturing Process
Cocoa Tree.

Chocolate production begins at the cocoa tree, where cocoa pods containing cocoa
beans in a cotton wool-like pulp are harvested between October and December

Fig.3 Cocoa Tree

Cocoa Beans.

The beans are placed between layers

of banana leaves for six days to drain
the pulp away, a method known as
‘heap’, before being dried in the sun,
packaged and sent to a factory for
chocolate making.
Fig.4 Cocoa Beans
 Chocolate Production Process in General

Step 1: Cleaning
The process of making chocolate starts with the cocoa beans being passed through a
machine that removes dried cocoa pulp, pieces of pod and other extraneous material.
The beans are carefully weighed and blended according to specifications. Finally,
the last vestiges of wood, jute fibres, sand, and even the finest dust are extracted by
powerful vacuum equipment. The separated cocoa bean husks are passed on to the
chemical industry which extracts valuable compounds.

Step 2: Roasting
To bring out the characteristic chocolate aroma, the beans are roasted in large rotary
cylinders. Depending upon the variety of the beans and the desired end result, the
roasting lasts from 30 minutes to two hours at temperatures of 250 degrees
Fahrenheit and higher. As the beans turn over and over, their moisture content drops,
their color changes to a rich brown, and the characteristic aroma of chocolate
becomes evident. Although all steps are important, proper roasting is one of the keys
to good flavor.

Step 3: Shell Removal

The cocoa beans are cooled quickly and their thin shells, which have become brittle
by roasting, are removed. A giant winnowing machine that passes the beans between
serrated cones so they are cracked rather than crushed. In the process, a series of
mechanical sieves separate the broken pieces into large and small grains while fans
blow away the thin, light shell from the meat or "nibs." Here's where the first secrets
of the chocolate manufacturer comes in. The nibs are blended, combining as many
as 8-10 varieties. It is control of these subtle mixtures that maintain constant quality
and brings out the flavor of each particular variety of chocolate.
Step 4: Nibs are ground
The nibs, which contain about 53 % cocoa butter, pass through refining mills and
are ground between large grinding stones or heavy steel discs creating a cocoa paste.
The paste is subjected to hydraulic pressure, and the cocoa butter flowing out is a
pure and valuable fat with a marked aroma; after filtering and purifying it looks very
much like ordinary butter.
The cocoa butter has important functions. It not only forms part of every recipe, but
it also later gives the chocolate its fine structure, beautiful lustre and delicate,
attractive glaze. The heat generated by grinding causes the cocoa butter or fat to melt
and form a fine paste or liquid known as chocolate "liquor". When the liquid is
poured into molds and allowed to solidify, the resulting cakes are unsweetened or
bitter chocolate.

Step 5: Cocoa is separated from Cocoa Butter

Up to this point, the manufacturing of cocoa and chocolate is identical. The by-
product of cocoa, cocoa butter, is the essential component of chocolate… about 25%
of the weight of most chocolate bars. To make cocoa powder chocolate liquor is
pumped into hydraulic presses weighing up to 25 tons, and when the pressure is
applied, 80% cocoa butter is removed. The fat drains away through metallic screens
as a yellow liquid, and then is collected for use in chocolate manufacturing. Cocoa
butter, unique among vegetable fats, is a solid at normal room temperature and melts
at 89 to 93 degrees Fahrenheit… just below body temperature. With proper storage
conditions, cocoa butter can be kept for years without spoiling.

Step 6: Other ingredients are added to the

Chocolate Liquor
Milk chocolate is made by adding milk, sugar, cocoa butter and other ingredients to
the bitter chocolate liquor. At this point, Chocolate is prepared in according to
individual recipes. The blending of the various types of cocoa pastes and other
ingredients determine the ultimate taste. The ingredients go into a mixer with
rotating, kneading arms until the result is a homogeneous, paste-like mixture with a
pleasant taste, but it still feels gritty to the palate.
Step 7: Conching machines knead the Chocolate
Paste
This process develops flavors and changes the texture during controlled
temperatures. It’s the last and most important refining process, which allows the
separate flavors of the individual ingredients to combine. Conches [the paddles of
the early machines resembled conch shells] are equipped with heavy rollers that
plow back and forth through the chocolate paste, anywhere from a few hours to
several days. Contemporary technologies can grind the chocolate particles extremely
fine, which can reduce conching times. Swiss and Belgian chocolates, are conched
as much as 96 hours. Some chocolates are not conched at all, or for only 4 to 12
hours.
Under regulated speeds and temperatures, these rollers can produce different degrees
of agitation and aeration to create distinct chocolate flavors. The process can
eliminate any remaining bitterness by aerating the chocolate and expelling volatile
acids. Additional cocoa butter and lecithin are added which help to achieve the
characteristic velvet smoothness. And as the ultimate homogeneity of the ingredients
is developed, a soft film of cocoa butter begins to form around each of the extremely
small particles. The chocolate no longer seems sandy, but dissolves meltingly on the
tongue. It has attained the outstanding purity which gives it its reputation. The last
stage of conching Swiss or Belgian chocolate is a magnificent sight… huge paddles
rolling slowly through great vats of chocolate, smooth and creamy and thick.

Step 8: Chocolate is Tempered by Heating, Cooling

& Reheating
This thickens the chocolate and imparts the right flow properties for filling the
moulds. This complex operation is performed in the tempering plant and is
necessary to give the final chocolate product a delicate composition, a uniform
structure and a well-rounded flavor. The storage life is also increased in this way.
The still warm conched chocolate is placed in a tempering machine so that it can be
slowly and steadily cooled. Cooling chocolate at a fixed rate keeps the flavor from
being compromised, and prevents separation when the chocolate is poured into bar
molds. Proper tempering also results in a silky sheen and crisp "snap" when
broken… another sign of a superior quality chocolate bar. The tempered chocolate
is pored into molds of many sizes, from individual sized bars to a ten pound blocks
used by confectionery manufacturers.

Step 9: Liquid Chocolate is Temporary Stored

A necessary step, conches are always filled with the largest amounts of chocolate
for efficiency, the molding machines can only accept small amounts of chocolate
paste at one time, in order to shape it into bars, chocolates and other products.
Chocolate is frequently shipped in a liquid state to other food manufacturers, or it
can be stored for short periods of time. For longer periods, it is solidified, usually in
the form of hundredweight blocks. These blocks must be reheated before further
processing so that they liquefy again.
 Chocolate Manufacturing Process
Inside a chocolate factory, the beans are heated inside a continuous roaster as they
travel along a conveyor belt. The time of this process varies depending on the flavour
required. Once suitably roasted, they are broken down into small pieces and their
brittle shells are removed, leaving only the meaty centres of the beans, the ‘nibs’,
which contain the essential cocoa butter for chocolate production. A mill grinds
these nibs into a thick brown liquid known as ‘cocoa liquor’, the basis of all
chocolate products, which is then mixed with varying amounts of sugar and milk
depending on the required type of chocolate. Typically, dark chocolate consists of
70% cocoa liquor, while milk and white chocolate have 30%.

Fig.5 Cocoa Beans Drying

Chocolate Manufacturing Process
Chocolate Manufacturing Process
Thank You