Method for Producing Chocolate Products

Abstract

The present invention provides a method of making a chocolate product, the method comprising the steps of: a) size reducing a chocolate ingredient mixture followed by conching the chocolate ingredient mixture; and b) ball milling the chocolate ingredient mixture formed in step a) to form a chocolate product comprising a particle size distribution that is reduced compared to the chocolate ingredient mixture formed in step a), wherein at the end of step a) the chocolate ingredient mixture comprises a particle size distribution with a D90 value of 20 to 100 μm, and at the end of step b) the chocolate product comprises a particle size distribution with a D90 value of 15 to 35 μm and that is smaller than the particle size distribution formed in step a).

Description

[Technical Field]

[0001] The present invention relates to a method for producing a chocolate product. [Background technology]

[0002] A typical chocolate manufacturing process includes the following steps: 1) grinding cocoa nibs and mixing the resulting cocoa product with the remaining chocolate ingredients; 2) reducing the size of the chocolate ingredient mixture by refining to reduce the particle size to the desired particle size of the final chocolate product; 3) conching the chocolate product; and 4) tempering and solidifying the chocolate product to form a solid chocolate product.

[0003] The conching step breaks down agglomerates and distributes the cocoa butter evenly within the chocolate ingredient mixture. The conching step typically does not significantly reduce particle size, so a refining step is required to reduce the particle size to the desired size to produce a smooth, non-gritty chocolate product. Size reduction (e.g., refining) steps typically require a long time and can have low throughput. By reducing the particle size to the desired low particle size of the final product (typically 12-28 μm) in the initial refining step, the refining equipment often wears out and therefore may need to be replaced periodically to ensure the final product remains consistent.

[0004] It would therefore be advantageous to provide a method of producing a chocolate product in which the extent of the initial size reduction step is reduced, increasing the throughput of the chocolate product and increasing manufacturing efficiency.

[0005] It would be advantageous to provide a method of making a chocolate product in which the particle size at the end of the initial size reduction step is larger than desired in the final product, thereby reducing the likelihood or frequency of damage or wear to size reduction equipment during production. It would be advantageous to provide a method of making a chocolate product that increases the life of the equipment and reduces downtime for maintenance.

[0006] It would also be advantageous to provide a method of producing a chocolate product in which the resulting chocolate product is of consistent quality, and in particular, the final product has a desired particle size distribution and produces a desired mouthfeel without a grainy or sticky texture.

[0007] It is an object of embodiments of the present invention to overcome one or more problems of the prior art, whether or not they are explicitly disclosed herein. Summary of the Invention [Means for solving the problem]

[0008] According to a first aspect of the present invention, a method for producing a medicament for stimulating ... a) reducing the size of a chocolate ingredient mixture, followed by conching the chocolate ingredient mixture; b) ball milling the chocolate ingredient mixture formed in step a) into a chocolate product comprising a reduced particle size distribution, wherein the chocolate ingredient mixture at the end of step a) comprises a particle size distribution having a D90 value of 20 to 100 μm, and the chocolate product at the end of step b) comprises a particle size distribution having a D90 value of 15 to 35 μm and smaller than the particle size distribution formed in step a).

[0009] Particle size distribution and D90 values ​​may be measured, for example, using a Malvern Mastersizer 3000 (supplied by Malvern Panalytical Ltd, UK).

[0010] The ball milling step in step b) after step a) can be advantageous because it reduces the amount of size reduction required in step a) of the production process, since the particle size distribution of the chocolate ingredient mixture at the end of step a) remains higher than the desired particle size distribution of the final chocolate product. The throughput of the ball milling step is significantly higher than that of the size reduction step, and therefore, by reducing the duration of the size reduction step and adding a ball milling step, the method of the present invention increases the overall throughput of the chocolate product compared to production methods that do not include a ball milling step after the initial size reduction and conching steps, thereby increasing production efficiency and reducing costs.

[0011] In some embodiments, the size reduction step comprises a refining step. In some embodiments, the size reduction step is carried out using at least one roll refiner. The roll refiner can be a two-roll roll refiner, a three-roll roll refiner, or a five-roll roll refiner. The size reduction step can be carried out using at least two, three, four, or five roll refiners. The at least two roll refiners can be arranged in series or in parallel.

[0012] In embodiments where the size reduction step includes at least two roll refiners, the roll refiners can be the same or different. Step a) can include reducing the size of the chocolate ingredient mixture by refining with a two-roll roll refiner followed by a five-roll roll refiner. Step a) can include reducing the size of the chocolate ingredient mixture by refining with a three-roll roll refiner followed by a five-roll roll refiner. Step a) can include reducing the size of the chocolate ingredient mixture by refining with a two-roll roll refiner followed by a three-roll roll refiner. Step a) can include reducing the size of the chocolate ingredient mixture by refining with a two-roll roll refiner followed by a three-roll roll refiner, followed by a five-roll roll refiner.

[0013] In some embodiments, the size reduction step comprises a milling step. In some embodiments, the milling size reduction step is performed using at least one hammer mill. In some embodiments, the size reduction step comprises a grinding step.

[0014] Prior to the size reduction step of step a), the chocolate ingredient mixture may comprise a particle size distribution with a D90 value of at least 50 μm, 100 μm, 200 μm, 300 μm, 400 μm, 500 μm, 700 μm, 900 μm, or at least 1000 μm. Prior to the size reduction step of step a), the chocolate ingredient mixture may comprise a particle size distribution with a D90 value of no more than 3000 μm, 2500 μm, 2000 μm, 1800 μm, 1600 μm, or preferably no more than 1500 μm. The chocolate ingredient mixture prior to the size reduction step may comprise a particle size distribution having a D90 value of 50 μm to 3000 μm, or 100 μm to 2000 μm, or 100 μm to 1750 μm, or 100 μm to 1500 μm, or 200 μm to 1500 μm.

[0015] The particle size distribution of the chocolate ingredient mixture after the size reduction step of step a) may comprise a D90 value of 100 μm or less, 80 μm or less, 60 μm or less, 50 μm or less, or 40 μm or less. The particle size distribution of the chocolate ingredient mixture after the size reduction step of step a) may comprise a D90 value of at least 20 μm, 25 μm, 30 μm, 35 μm, or at least 40 μm. The particle size distribution of the chocolate ingredient mixture after the size reduction step of step a) may comprise a D90 value of 100 μm to 20 μm, or 80 μm to 20 μm, or 60 μm to 20 μm, or 40 μm to 20 μm, or 40 μm to 28 μm, or 35 μm to 28 μm, or 35 μm to 30 μm.

[0016] In some embodiments, the particle size distribution of the chocolate ingredient mixture is reduced in the size reduction step of step a) from a D90 value of 100 μm to 1800 μm to a D90 value of 20 μm to 80 μm. In some embodiments, the particle size distribution of the chocolate ingredient mixture is reduced in the size reduction step of step a) from a D90 value of 100 μm to 1500 μm to a D90 value of 20 μm to 80 μm. In some embodiments, the particle size distribution of the chocolate ingredient mixture is reduced in the size reduction step of step a) from a D90 value of 100 μm to 1700 μm to a D90 value of 20 μm to 40 μm. In some embodiments, the particle size distribution of the chocolate ingredient mixture is reduced in the size reduction step of step a) from a D90 value of 100 μm to 1500 μm to a D90 value of 20 μm to 40 μm. In a preferred embodiment, the particle size distribution of the chocolate ingredient mixture is reduced in step a) of size reduction from a D90 value of at least 150 μm to a D90 value of 30 μm to 35 μm. Size reducing the chocolate ingredient mixture to a particle size distribution having a higher D90 value than the desired particle size distribution of the final product can be advantageous because it can reduce the initial size reduction time of the manufacturing process, thereby saving time and energy. Size reducing the chocolate ingredient mixture to a particle size distribution having a higher D90 value than the desired particle size distribution of the final product can be advantageous because it can prevent damage or wear to the size reduction equipment, thereby extending the life of the equipment and reducing downtime for maintenance. In an embodiment in which the size reduction step is a refining step performed with at least one roll refiner, size reducing the chocolate ingredient mixture to a particle size distribution having a higher D90 value than the desired particle size distribution of the final product can be advantageous because it can prevent damage or wear to the rollers.

[0017] The conching step may comprise a wet conching step or a dry conching step, hi some embodiments, the conching step may comprise a dry conching step followed by a wet conching step.

[0018] In some embodiments, the particle size may not be further reduced in a conching step after the size reduction step in step a) and before the ball milling step in step b). The particle size of the chocolate ingredient mixture after the conching step in step a) may comprise a D90 value of 100 μm to 20 μm, or 80 μm to 20 μm, or 60 μm to 20 μm, or 40 μm to 20 μm, or 40 μm to 28 μm, or 35 μm to 28 μm. In a preferred embodiment, the particle size of the chocolate ingredient mixture at the end of step a) after the size reduction and conching steps may comprise a D90 value of 35 μm to 30 μm. The particle size of the chocolate ingredient mixture after the conching step in step a) may be larger than the desired particle size of the chocolate product.

[0019] During step b), the particle size distribution of the chocolate ingredient mixture can be reduced to the desired particle size distribution of the chocolate product produced at the end of step b). The chocolate product after step b) can comprise a particle size distribution having a D90 value of 15 μm to 35 μm, or 15 μm to 25 μm, or 15 μm to 20 μm, or 20 μm to 30 μm, or 20 μm to 28 μm, or 22 μm to 27 μm, or a D90 value of 22 μm to 25 μm. This embodiment can be advantageous because it creates a chocolate product with a desired mouthfeel without the grainy texture that can be experienced with higher particle sizes or the sticky texture that can be experienced with lower particle sizes.

[0020] The D90 particle size of the chocolate ingredient mixture at the end of step a) may be reduced by 2 μm to 80 μm in the ball milling step b). In some embodiments, the D90 particle size of the chocolate ingredient mixture at the end of step a) may be reduced by 2 μm to 60 μm, or 2 μm to 40 μm, 2 μm to 30 μm, 2.5 μm to 25 μm, 2.5 μm to 20 μm, 2.5 μm to 15 μm, or 2.5 μm to 12 μm in the ball milling step b). In some embodiments, the D90 particle size of the chocolate ingredient mixture at the end of step a) may be reduced by 5 μm to 15 μm or 3 μm to 15 μm in the ball milling step b).

[0021] The ball milling step of step b) may be carried out at a temperature of 30°C to 80°C, or 30°C to 70°C, or 35°C to 65°C, or 40°C to 65°C, or 45°C to 80°C, or 45°C to 65°C. The reduced particle size chocolate product may exit the ball mill at a product temperature of 70°C or less. In some embodiments, the reduced particle size chocolate product may exit the ball mill at a product temperature of 50°C or less. The reduced particle size chocolate product may exit the ball mill at a product temperature of 68°C, 65°C, 62°C, 60°C, 58°C, 55°C, 52°C or less, or 50°C or less.

[0022] The ball milling step of step b) can be carried out in a ball mill, and the ball mill can be partially filled with beads. The ball mill can be at least 50% filled with beads, or at least 55%, 60%, 65%, 70%, 80%, or at least 90% filled with beads. The beads can be 2 mm to 8 mm in diameter. The beads can be selected from the group consisting of 3 mm beads, 4 mm beads, 5 mm beads, and combinations thereof. The ball mill can contain beads of two or more sizes. The ball mill can contain 3 mm beads and 5 mm beads. The amount of 3 mm beads can be 60% to 80% of the total amount of beads in the ball mill. The amount of 5 mm beads can be 20% to 40% of the total amount of beads in the ball mill. In some embodiments, the amount of 3 mm beads can be 60% to 80% of the total amount of beads in the ball mill, and the amount of 5 mm beads can be 20% to 40% of the total amount of beads in the ball mill. The beads can be of any suitable material, for example, steel, stainless steel, ceramic, or rubber.

[0023] The ball milling step may be carried out in a ball mill having an internal shaft tip speed of at least 3 m / s. The ball milling step may be carried out in a ball mill having an internal shaft tip speed of at least 4 m / s, 5 m / s, or at least 6 m / s. The ball milling step may be carried out in a ball mill having an internal shaft tip speed of no more than 15 m / s, no more than 14 m / s, no more than 13 m / s, or no more than 12 m / s. The ball milling step may be carried out in a ball mill having an internal shaft tip speed of between 3 m / s and 15 m / s, between 4 m / s and 14 m / s, or between 4 m / s and 12 m / s.

[0024] The chocolate ingredient mixture comprises at least one ingredient selected from the group comprising cocoa nibs, cocoa powder, cocoa butter, and cocoa liquor.

[0025] The term "chocolate" in the context of the present invention is not limited by the various definitions of chocolate provided by governments and competent authorities. "Chocolate" is simply a product containing a fat phase, which includes a cocoa product and optionally a sweetener. Other optional ingredients of chocolate include dairy ingredients (e.g., milk fat and milk powder).

[0026] The chocolate ingredient mixture may include at least one fat. The fat may include cocoa butter. The cocoa butter may be natural cocoa butter isolated from cocoa mass. The fat may be cocoa butter, butterfat, cocoa butter equivalent (CBE), cocoa butter substitute (CBS), vegetable fat that is liquid at standard ambient temperature and pressure (SATP, 25°C and 100 kPa), or any combination of the above. In certain embodiments, the chocolate ingredient mixture includes cocoa butter.

[0027] CBE is defined in Directive 2000 / 36 / EC. Suitable CBEs include illipe, Borneo tallow, tengkawang, palm oil, sal, shea, kokum gurgi, and mango kernel. CBEs are typically used in combination with cocoa butter. In one embodiment, the chocolate contains 5% by weight or less of CBE.

[0028] The chocolate ingredient mixture may contain cocoa butter substitutes (CBS) (sometimes known as cocoa butter substitutes, or CBR) in addition to, or instead of, some or all of the cocoa butter. Such chocolate materials are also known as compound chocolate. Suitable CBS include CBS laurate and CBS non-laurate. CBS laurates are short-chain fatty acid glycerides. While their physical properties vary, they all have a triglyceride structure that makes them compatible with cocoa butter. Suitable CBS include those based on palm kernel oil and coconut oil. CBS non-laurate consists of fractions obtained from hydrogenated oils. The oils are selectively hydrogenated with the formation of trans acids, which increases the solid phase of the fat. Suitable sources of CBS non-laurate include soybean oil, cottonseed oil, peanut oil, rapeseed oil, and corn (maize) oil.

[0029] The chocolate may contain at least one vegetable fat that is liquid at standard ambient temperature and pressure (SATP, 25°C and 100 kPa). Suitable vegetable fats include corn oil, cottonseed oil, rapeseed oil, palm oil, safflower oil, and sunflower oil. The chocolate ingredient mixture may contain up to 15, 10, or 5% by weight of vegetable fat.

[0030] The chocolate ingredient mixture may contain at least 5%, 10%, 15%, 20%, 25%, 30%, 35% or at least 40% by weight of cocoa butter and / or cocoa butter substitute.

[0031] The chocolate ingredient mixture may include at least one emulsifier. The emulsifier may be a natural or artificial emulsifier. The chocolate ingredient mixture may include 5% or less by weight of emulsifier, or 4%, 3%, 2%, 2.5%, 1%, or 0.5% or less by weight of emulsifier. Suitable emulsifiers include, for example, lecithin, ammonium phosphatide, and PGPR.

[0032] In some embodiments, the chocolate ingredient mixture may include at least one dairy product. Suitable dairy products include cream, whole milk, skim milk, and / or whey. The dairy product may include milk powder solids, such as milk powder, cream powder, or whey powder. The chocolate ingredient mixture may include 2-50% by weight of dairy product. The chocolate ingredient mixture may include 10%-40% by weight of dairy product, 15%-35% by weight, or 20%-40% by weight of dairy product.

[0033] In some embodiments, the chocolate ingredient mixture may include at least one sweetener. In some embodiments, the chocolate ingredient mixture may include at least one natural and / or artificial sweetener. The sweetener may include a saccharide, which may be selected from the group including monosaccharides, disaccharides, oligosaccharides, polysaccharides, or combinations thereof. Each saccharide sweetener may be independently selected from the group consisting of glucose, fructose, lactose, galactose, dextrose, polydextrose, inverted fructose syrup, inverted corn syrup, and sucrose. In some embodiments, the sweetener may include or be sucrose. The sweetener may include a polyol (polyhydric alcohol), which may be selected from the group consisting of sorbitol, mannitol, maltitol, erythritol, xylitol, isomalt, and any combination thereof. The sweetener may have a sweetening power greater than that of sucrose. The sweetener may be selected from the group including water-soluble sweeteners, water-soluble artificial sweeteners, dipeptide-based sweeteners, protein-based sweeteners or bulking agents, or combinations thereof. The amount of sweetener may be 55% or less by weight of the chocolate ingredient mixture, or 50%, 45%, 40%, 35%, 30%, 25%, 20%, or 15% or less by weight of the chocolate ingredient mixture.

[0034] In some embodiments, the chocolate ingredient mixture may include at least one flavoring. The flavoring may be a natural flavoring or an artificial flavoring. Examples of suitable flavorings include, but are not limited to, spearmint oil, cinnamon oil, peppermint oil, bitter almond oil, cassia oil, vanilla, citrus oils including lemon, orange, lime, and grapefruit, and fruit essences including apple, pear, peach, grape, strawberry, raspberry, and cherry, or aldehydes and esters such as cinnamyl acetate, cinnamaldehyde, citral diethyl acetal, dihydrocarbyl acetate, eugenyl formate, and p-methylamisole.

[0035] In some embodiments, the chocolate ingredient mixture in step a) comprises at least non-fat cocoa solids, cocoa butter and / or fat, and a sweetener. In some embodiments, the ingredient mixture in step a) comprises at least cocoa liquor, a sweetener, and cocoa butter. In other embodiments, the chocolate ingredient mixture in step a) may comprise milk chocolate, dark chocolate, white chocolate, or compound chocolate.

[0036] In some embodiments, no additional chocolate ingredients are added to the chocolate ingredient mixture during step a) or between steps a) and b). In alternative embodiments, additional ingredients may be added to the chocolate ingredient mixture during the size reduction step of step a). In some embodiments, additional ingredients may be added to the chocolate ingredient mixture during the conching step of step a).

[0037] In some embodiments, no additional chocolate ingredients are added to the chocolate ingredient mixture during step b), which may be advantageous because at the end of step a), the size-reduced chocolate ingredient mixture may be transferred to a ball milling step in step b) for a final size reduction step to produce a chocolate product of the desired particle size.

[0038] The chocolate ingredient mixture may be liquid during step a), between steps a) and b), and during step b). The chocolate ingredient mixture may be a paste during the size reduction step of step a) and then conched to a liquid or paste during the conching step of step a). The chocolate ingredient mixture at the end of step a) may be stored as a liquid before step b). The size-reduced chocolate product formed at the end of step b) may be a liquid or a paste. In steps following step b), the chocolate product may be stored as a liquid before solidifying into a solid chocolate product.

[0039] In some embodiments, in a step following step b), the chocolate product may be cooled by passing it through a suitable heat exchanger so that the temperature of the chocolate product may be reduced to a temperature of between 40° C. and 60° C. or between 40° C. and 50° C. After the temperature of the chocolate product has been reduced, the chocolate product may be stored as a liquid before solidifying into a solid chocolate product.

[0040] In a step following step b), the chocolate product may be tempered before solidifying into a solid chocolate product. In the tempering step, the liquid chocolate product is subjected to tempering to control the crystallization of the cocoa butter in the chocolate mass. Tempering may or may not be necessary depending on the fat components used. Tempering, as is generally known in the art, may be carried out at a temperature not exceeding 50°C, preferably at least 35°C. The preferred temperature range for the tempering step is 35°C to 40°C.

[0041] The chocolate product may be solidified by molding. The chocolate product may be solidified by filling a molded shell followed by lining, thereby creating a solid chocolate shell or molded shape. The chocolate product may be solidified by encasing the chocolate product over another product, such as a confectionery product. The chocolate product may be solidified by cold stamping the product into the desired shape.

[0042] In a second aspect of the present invention, there is provided a chocolate product obtained or obtainable by the process of the first aspect of the present invention.

[0043] The chocolate product may be a milk chocolate product. The chocolate product may be a non-dairy or low-dairy product, such as a dark chocolate product or a white chocolate product. The chocolate product may be stored as a liquid before solidifying into a solid chocolate product in a subsequent step b). The solid chocolate product may be in the form of a tablet, bar, shell, or any other suitable format. The solid chocolate product may be a filled chocolate confectionery.

[0044] In some embodiments, the chocolate product may be a chocolate coating. In some embodiments, the chocolate product may be a chocolate filling. [Brief explanation of the drawings]

[0045] In order that the present invention may be more clearly understood, embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0046] [Figure 1] 1 illustrates a flow diagram illustrating a first embodiment of a method for producing chocolate of the present invention, the method comprising a size reduction refining step followed by a conching step followed by a ball milling step. [Figure 2] FIG. 1 illustrates a flow diagram illustrating a second embodiment of a method for producing a chocolate of the present invention, which comprises multiple refining size reduction steps followed by multiple conching steps followed by a ball milling step. DETAILED DESCRIPTION OF THE INVENTION

[0047] Example 1 A flow diagram of a first embodiment of the method for producing chocolate of the present invention is illustrated in FIG.

[0048] The method (1) for producing a chocolate product (10) involved adding a chocolate ingredient mixture (2) to a roll refiner where it underwent size reduction, a roll refining step (4), followed by a conching step (6). The particle size distribution of the chocolate ingredient mixture was reduced from a D90 value of at least 150 μm before the roll refining step (4) to 30-35 μm after the roll refining step (4). The particle size was not significantly further reduced in the conching step (6). The particle size distribution was measured using a Malvern Mastersizer 3000 (supplied by Malvern Panalytical Ltd, UK).

[0049] Following the conching step (6), the chocolate ingredient mixture, having a particle size distribution with a D90 value of 30-35 μm, entered a ball milling step (8) where the particle size was further reduced by 2.5-12 μm. The output from the ball milling step (8) was a chocolate product (10) containing a particle size distribution with a D90 value of 23-27.5 μm. The chocolate product (10) was then stored in a storage area (12) before solidifying into the final solid chocolate product.

[0050] The examples and methods of the present invention generally are not limited to producing chocolate products from any particular starting ingredients: the methods may be used with any ingredients typically used in chocolate manufacture, including, but not limited to, cocoa source ingredients such as cocoa powder or cocoa liquor, fat sources such as cocoa butter or vegetable fats, sweeteners, and / or dairy products.

[0051] Chocolate product characteristics Chocolate Products A-F were produced according to the method of the first embodiment of the present invention described above in Example 1. The ingredients of Chocolate Products A-F were 47% sugar by weight, 18% cocoa butter by weight, 23% milk powder by weight, 11% cocoa by weight, and 1% soy lecithin by weight. The ball mill used in the ball milling step of producing Chocolate Products A-F was a 7-liter horizontal ball mill, which was filled with 77% 3 mm beads and 23% 5 mm beads to produce a bead loading level of 76%. The shaft speed of the ball mill was set to 11 m / s, 13 m / s, or 16 m / s, and the throughput of the ball mill was set to 380, 260, 150, or 80 kg / hr. All parameter combinations are shown in Table 1.

[0052] The temperature of the chocolate product (exit temperature) and the D90 particle size distribution value of the chocolate product were measured after ball milling and the data are shown in Table 1.

[0053] [Table 1]

[0054] Instead of refining the chocolate ingredient mixture to 23-27.5 μm and conching without a ball milling step, by refining the chocolate ingredient mixture to 30-35 μm (D90 particle size distribution before ball milling), conching, and then ball milling the chocolate ingredient mixture to the desired particle size of 23-27.5 μm, the throughput of the manufacturing process can be increased by 25% and the life of the refining rollers can be significantly extended, thereby minimizing downtime and maintenance costs without compromising chocolate product properties such as flavor, texture, and mouthfeel.

[0055] As shown by the data in Table 1, the chocolate products produced following the ball milling step according to the manufacturing process of the present invention produce a uniform chocolate product over a range of ball milling conditions in which the D90 particle size distribution of the chocolate product is consistently within the desired target range of 23 to 28 μm.

[0056] Example 2 A second embodiment of a method for making chocolate of the present invention is illustrated in Figure 2. The method (101) for making a chocolate product (110) included feeding a chocolate ingredient mixture (102) into multiple roll refiners for multiple size reduction roll refiner steps (104) such that the chocolate ingredient mixture (102) could pass through the multiple roll refiners in parallel. The multiple roll refining steps (104) were followed by multiple conching steps (106) in parallel. The particle size of the chocolate ingredient mixture was reduced from a D90 value of at least 150 µm before the roll refining step (104) to 30-35 µm after the roll refining step (104). The particle size was not further reduced in the conching step (106).

[0057] The particle size reduced chocolate ingredient mixture obtained from the conching step (106) entered a ball milling step (108) where the particle size was further reduced by 2.5-12 μm, and the output from the ball milling step (108) was a chocolate product (110) having a particle size distribution of 23-27.5 μm. The ball milling step (108) was essentially the same as the ball milling step of the first embodiment of the present invention, and the resulting chocolate product (110) was essentially the same as the resulting chocolate product of the first embodiment of the present invention described in Example 1.

[0058] Typical throughput of the roll refiner (104) is 900-1200 kg / h. Reducing the particle size distribution of the chocolate ingredient mixture to 30-35 μm during the roll refining step (104) instead of the desired particle size distribution of the final chocolate product (23-27.5 μm) increases refiner throughput in the manufacturing process. The throughput of the ball milling (108) step can be as high as 5000-6000 kg / h, and therefore adding a ball milling (108) step at the end of the manufacturing process after the conching step (106) increases the manufacturing efficiency of the manufacturing method according to the present invention. The throughput of the chocolate product (110) increases by 25% when compared to a method that does not include a ball milling step after the refining and conching steps, since the roll refining step reduces the particle size of the chocolate ingredients to the desired particle size of the final product.

[0059] The above embodiments are described by way of example only: many modifications are possible without departing from the scope of the invention as defined in the appended claims.

Claims

1. 1. A method for producing a chocolate product, comprising the steps of: a) size reducing a chocolate ingredient mixture followed by conching said chocolate ingredient mixture; b) ball milling the chocolate ingredient mixture formed in step a) to form a chocolate product comprising a reduced particle size distribution compared to the chocolate ingredient mixture formed in step a); wherein the chocolate ingredient mixture at the end of step a) comprises a particle size distribution with a D90 value of 20 to 100 μm, and the chocolate product at the end of step b) comprises a particle size distribution with a D90 value of 15 to 35 μm and smaller than the particle size distribution formed in step a).

2. 2. The method of claim 1, wherein the size reduction step of step a) comprises refining, preferably with at least one roll refiner.

3. 3. The method of claim 2, wherein step a) comprises refining the chocolate ingredient mixture in a two-roll refiner followed by a five-roll refiner.

4. 4. The method of any one of claims 1 to 3, wherein the D90 particle size distribution of the chocolate ingredient mixture before step a) is less than or equal to 1500 μm.

5. 5. The method of claim 4, wherein the D90 particle size distribution of the chocolate ingredient mixture is reduced in the size reduction step of step a) from 100-1500 μm to 20-100 μm, preferably to 28-40 μm.

6. 6. The method of any one of claims 1 to 5, wherein the D90 particle size distribution of the chocolate ingredient mixture formed in step a) is reduced by 2 to 80 μm in the ball milling step of step b).

7. 7. The method according to any one of claims 1 to 6, wherein the ball milling step is carried out at 30 to 80°C.

8. 8. The method of any one of claims 1 to 7, wherein the chocolate ingredient mixture comprises at least one cocoa ingredient selected from the group comprising cocoa nibs, cocoa powder, cocoa butter, and cocoa liquor.

9. A method according to any one of the preceding claims, wherein after step b) the chocolate product is stored as a liquid before solidifying into a solid chocolate product.

10. 10. The method of any one of claims 1 to 9, wherein no additional chocolate ingredients are added to the chocolate ingredient mixture during step a), between steps a) and b), and / or during step b).

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