Chocolate Production Process Using Dual Grinding Lines
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Solution Overview
Problem
Current chocolate production processes are energy-intensive due to the lengthy conching step, which is time-consuming and limits manufacturing capacity and speed.
Innovation Solution
A process involving the formation of two separate mixtures, grinding them in different grinding means, combining them, and homogenizing with added fat before conching, allowing for reduced conching time and increased capacity using existing equipment with low investment costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional conching process is used to develop flavour and reduce viscosity, then product quality is improved, but energy consumption increases and production time increases
Solution Approach 1:
The invention divides the chocolate production process into two separate grinding lines processing different mixtures (first mixture with high fat content and second mixture with low fat content), which are then combined and conched together. This segmentation allows each line to be optimized independently, reducing overall conching time and energy consumption while maintaining product quality
2Reliability
If traditional conching process is used to develop flavour and reduce viscosity, then product quality is improved, but production capacity is limited
Solution Approach 1:
By implementing two separate grinding lines that process different mixtures in parallel, the invention doubles the production capacity compared to a single line, while the combined mixture is conched together to ensure quality consistency
Solution Approach 2:
The invention performs preliminary grinding and preparation of two separate mixtures before combining them for conching. This preliminary action allows the actual conching process to be shortened while still achieving the desired flavour development and viscosity reduction, thereby increasing production capacity
3Reliability
If traditional conching process is used to develop flavour and reduce viscosity, then product quality is improved, but manufacturing speed is limited
Solution Approach 1:
The invention performs preliminary grinding and preparation of two separate mixtures with different fat contents before combining them. This preliminary action optimizes the mixture composition to reduce the time required for flavour development and viscosity reduction during conching, thereby increasing manufacturing speed while maintaining quality
4Productivity
If separate grinding lines are used to increase capacity, then production capacity is improved, but process complexity increases
Solution Approach 1:
The invention merges the outputs of two separate grinding lines by combining the first mixture and second mixture into a single conching process. This merging approach allows the benefits of parallel processing (doubled capacity) while consolidating the flavour development and viscosity reduction steps in one conching stage, thereby managing process complexity
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 reduces conching time, doubles manufacturing capacity, and optimizes equipment use by processing components in separate lines, achieving similar product quality to traditional methods while minimizing energy consumption.
Implementation Method 1
The mixture is homogenized, for example in a homogenizer, with incorporation of air
Implementation Method 2
Conching is a flavour-developing step which involves the intimate mixing or kneading of the chocolate ingredients
Implementation Method 3
conching the third mixture to form the chocolate or chocolate-like product
Data Source
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AI summary
A process for producing chocolate or a chocolate-like product comprises: (i) forming a first mixture comprising components of the chocolate or chocolate-like product; (ii) grinding the first mixture in first grinding means; (iii) forming a second mixture comprising components of the chocolate or chocolate-like product; (iv) grinding the second mixture in second grinding means different from the first grinding means; (v) combining the first and second mixtures to form a third mixture; and (vi) conching the third mixture to form the chocolate or chocolate-like product.