Chocolate Crumb Process Sugar Crystallization Control
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Solution Overview
Problem
The existing processes for manufacturing chocolate crumb often result in inconsistent flavor and texture due to overexposure to heat and moisture, leading to unwanted flavor profiles and equipment fouling, as they rely on critical parameters for sugar crystallization and phase change that are difficult to control.
Innovation Solution
A process involving the mixing of milk and sugar to form sweetened condensed milk, which is then heated to a controlled temperature range of 85 to 110°C for a specific duration before adding cocoa mass/liquor, followed by sugar crystallization and drying to produce chocolate crumb, optimizing the conditions for desirable handling and texture profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the sweetened condensed milk is held at elevated temperature for extended period to improve flavor development, then the Maillard reaction is enhanced, but unwanted flavor profiles and equipment fouling occur
Solution Approach 1:
The sweetened condensed milk is pre-heated to the processing temperature (85-110°C) before mixing with cocoa liquor, ensuring the temperature is already optimized for the Maillard reaction. This preliminary temperature adjustment allows the reaction to proceed efficiently during the mixing and crystallization phases without requiring extended holding times that would cause flavor degradation and equipment fouling.
Solution Approach 2:
The invention specifies a precise temperature range (85-110°C) and time range (10-60 minutes) for heating the sweetened condensed milk, optimizing the Maillard reaction conditions. By controlling these parameters within defined boundaries, the process achieves consistent flavor development while preventing the harmful effects of overexposure to heat and moisture.
2Manufacturing precision
If the heating temperature and time are increased to enhance Maillard reaction, then caramel flavor generation is improved, but the crumb texture becomes degraded and equipment fouling increases
Solution Approach 1:
The invention defines specific parameter ranges: temperature of 85-110°C and time of 10-60 minutes for heating sweetened condensed milk. These optimized parameters enable sufficient Maillard reaction for desirable caramel flavors while preventing excessive heat exposure that would degrade crumb texture and cause equipment fouling.
Solution Approach 2:
The process monitors and controls the heating parameters to ensure the sweetened condensed milk reaches and maintains the optimal temperature range before mixing with cocoa liquor. This controlled approach ensures consistent flavor development while preventing the harmful effects of uncontrolled overheating.
3Ease of manufacture
If conventional batch process is used for crumb preparation, then production flexibility is maintained, but inconsistent quality and taste are achieved
Solution Approach 1:
The sweetened condensed milk is pre-prepared and pre-heated to the specific temperature range (85-110°C) before being mixed with cocoa liquor. This preliminary preparation step ensures that the critical temperature parameter is already optimized, leading to consistent Maillard reaction and flavor development across batches while maintaining the flexibility of batch processing.
Solution Approach 2:
The invention specifies precise parameter ranges for temperature (85-110°C) and time (10-60 minutes) during the heating stage, which when followed consistently, produce uniform flavor and texture quality in the final crumb product while allowing flexible batch production.
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 process enhances the flavor and texture of chocolate crumb, providing improved handling properties and reducing the risk of equipment fouling by maintaining the sweetened condensed milk at an elevated temperature before cocoa addition, ensuring consistent quality.
Implementation Method 1
heating the sweetened condensed milk to a temperature in the range of 85 to 110°C for a period of 10 to 60 minutes
Implementation Method 2
subjecting the mixture to conditions effective to bring about a sugar crystallisation in the mixture
Implementation Method 3
drying the mixture so as to form chocolate crumb
Data Source
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AI summary
A process is described for the preparation of chocolate crumb. A milk and sugar mixture is provided, or milk and sugar are mixed together so as to form a mixture, and liquid is evaporated from the mixture so as to form sweetened condensed milk. The sweetened condensed milk is heated to a temperature in the range of 75 to 1 10°C for a period of 10 to 60 minutes, and cocoa mass/liquor are added and mixed to sweetened condensed milk to form a mixture. The mixture is then subjected to conditions effective to bring about a sugar crystallisation in the mixture, and dried so as to form chocolate crumb.