Chocolate Crumb Sugar Crystallization Control
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Solution Overview
Problem
The existing processes for manufacturing chocolate crumb face challenges in achieving consistent quality and taste due to the Maillard reaction, which can result in unwanted flavor profiles and equipment fouling, especially when sugar crystallization occurs too quickly or under improper conditions.
Innovation Solution
A process involving a single reaction vessel where a milk and sugar mixture with total solids in the range of 81% to 88% is prepared, with cocoa mass/liquor added subsequently, and subjected to controlled conditions for sugar crystallization and drying, reducing fat expression and fouling while maintaining desirable texture and flavor profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sugar crystallization is allowed to proceed without control, then the phase change from paste to powder occurs, but the sugar crystallizes too quickly causing a powdery crumb and equipment fouling
Solution Approach 1:
The patent applies parameter changes by precisely controlling the total solids content (81-88%) and temperature parameters during sugar crystallization. This controlled parameter approach prevents rapid uncontrolled crystallization while maintaining efficient production, resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The patent implements feedback control by continuously monitoring the crystallization process and adjusting conditions to maintain optimal parameters. This feedback mechanism ensures consistent crumb texture while maintaining high productivity through controlled phase change.
2Reliability
If the Maillard reaction is promoted through prolonged heat and moisture, then caramel flavors are generated, but unwanted flavor profiles develop and equipment fouling increases
Solution Approach 1:
The patent applies preliminary action by pre-setting the total solids content to 81-88% before the crystallization process. This preliminary preparation establishes optimal conditions that promote controlled Maillard reaction for desirable flavors while preventing excessive reaction that would cause fouling, thus resolving the contradiction between reliability and harmful factors.
Solution Approach 2:
The patent uses parameter changes by maintaining specific total solids content (81-88%) and controlling temperature profiles to optimize the Maillard reaction. This controlled parameter approach generates desirable caramel flavors while minimizing unwanted side effects and equipment fouling.
3Productivity
If total solids content is not optimized prior to crystallization, then production efficiency varies, but inconsistent quality and taste of crumb result
Solution Approach 1:
The patent resolves this contradiction by establishing a specific parameter range for total solids content (81-88%) that simultaneously optimizes both production efficiency and crumb quality consistency. This parameter control ensures reliable phase change and consistent product quality while maintaining high productivity.
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 approach results in a chocolate crumb with improved handling properties, reduced fouling, and a consistent flavor profile by controlling sugar crystallization and maintaining optimal solids content, preventing the formation of a powdery crumb and enhancing the overall efficiency of the chocolate crumb production process.
Implementation Method 1
subjecting the mixture to conditions effective to bring about sugar crystallisation in the mixture
Implementation Method 2
drying the mixture so as to form chocolate crumb
Implementation Method 3
the Maillard reaction between proteins (present in milk and cocoa), water and reducing sugars (such as lactose, present in milk), which is responsible for the generation of caramel flavours in the crumb
Data Source
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AI summary
A process is described for preparing chocolate crumb. A milk and sugar mixture is provided, or milk and sugar are mixed together so as to form a mixture, and the mixture is modified so that the total solids are present in the range of 75% to 90% of the mixture. During the process of mixing and/or modifying the mixture, cocoa mass/liquor is added to the mixture. The mixture is then subjected to conditions effective to bring about sugar crystallisation in the mixture, and dried so as to form chocolate crumb.