Chocolate Conching System Using Taste-Changer and Thin Film Evaporator
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Solution Overview
Problem
Conventional conching methods for chocolate and cocoa mass require long residence times and high energy input to achieve improved sensory parameters like creaminess and low viscosity, which is inefficient and costly.
Innovation Solution
A system combining a taste-changer with a thin film evaporator, where the taste-changer subjects the edible mass to high shear stresses and the thin film evaporator further treats the mass to reduce viscosity and extract volatile components, with optional integration and humidification to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional conching methods are used to improve sensory parameters like creaminess and low viscosity, then the sensory quality is improved, but the residence time becomes very long (up to 48 hours) and energy input becomes very high
Solution Approach 1:
The invention changes the physical-chemical parameters of the chocolate mass by introducing controlled moisture (water or steam) during conching. This parameter change facilitates hydrolysis of triglycerides and improves flow properties, allowing achieving good sensory parameters with much shorter residence times (2-24 hours) compared to conventional dry conching (48 hours)
Solution Approach 2:
The invention replaces part of the mechanical agitation function with chemical hydrolysis reactions. By introducing moisture and allowing hydrolysis to occur, the system reduces reliance on prolonged mechanical mixing to achieve desired viscosity and creaminess, thereby reducing required residence time
2Manufacturing precision
If conventional conching methods are used to improve sensory parameters like creaminess and low viscosity, then the sensory quality is improved, but the energy consumption becomes very high
Solution Approach 1:
By changing the moisture content parameter and enabling hydrolysis reactions, the invention reduces the energy required for mechanical agitation and heating over long periods. The chemical reactions facilitate viscosity reduction and creaminess development more efficiently than conventional thermal-mechanical conching alone
3Manufacturing precision
If traditional roller refiner and conch method is used to achieve good sensory profile, then the sensory quality is improved, but the residence time becomes very long (up to 48 hours) and energy input becomes very high
Solution Approach 1:
The invention introduces moisture parameter changes during conching to accelerate the refining and conching processes. This enables achieving equivalent sensory profiles with residence times reduced from 48 hours to 2-24 hours, significantly improving production efficiency and throughput
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This combination allows for short residence times and low energy consumption while improving creaminess and reducing viscosity, achieving similar sensory profiles to traditional methods but with significant energy and cost savings.
Implementation Method 1
means (2,8,9) for subjecting said chocolate mass, prior to it being spread out, to high shear stresses
Implementation Method 2
a thin film evaporator to further treat the edible mass exiting the taste-changer
Implementation Method 3
an inlet for supplying a gas, typically hot air, to the spread edible mass to extract volatile components, such as organic acids, from the edible mass
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a system (1) for conching edible mass, in particular cocoa containing mass, such as chocolate, cocoa liquor or compound, comprising a shear device, in particular a so-called taste-changer (14), in turn comprising a housing (16), a shaft (17) rotatably mounted in the housing (16), means (19, 20) for subjecting the edible mass to high shear stresses, means (21, 22) for spreading the edible mass after it has been subjected to high shear, and an inlet (24, 25) for supplying a gas to the spread edible mass. The system further comprises a thin film evaporator (15) to treat the edible mass exiting the shear device (14).