Chocolate Tempering via Planetary Shear and Precise Cooling
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Solution Overview
Problem
Current continuous tempering processes for chocolate mass result in high viscosity and instability due to the formation of undesirable crystals, leading to a highly liquid state that complicates forming processes and requires extensive reheating, which increases energy consumption and limits the production of high-quality chocolate articles with stable βV-crystals.
Innovation Solution
A process involving a plate heat exchanger and crystallization unit with planetary mixers that cool the chocolate mass below the βV-crystal creation temperature, applying shear to convert the mass into highly viscous chocolate with pure βV-crystals, eliminating the need for reheating and allowing direct extrusion, while maintaining precise temperature control to prevent crystal formation in the cooling stage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the chocolate mass is cooled by passage through the cooling stage to a temperature below the βV-crystal creation temperature, then the formation of stable βV-crystals is promoted, but the mass becomes highly viscous and difficult to handle
Solution Approach 1:
The chocolate mass is pre-cooled in the cooling stage to a temperature below the βV-crystal creation temperature before entering the crystallization stage. This preliminary cooling action prepares the mass for controlled crystallization while maintaining workability by preventing premature crystal formation during handling and processing.
Solution Approach 2:
The system dynamically adjusts temperatures across different stages: the cooling stage operates at lower temperatures to prevent crystal formation, while the crystallization stage maintains optimal temperature for βV-crystal development. This dynamic temperature control allows the mass to transition from a handleable state to a crystallized state at the appropriate processing stage.
2Stability of the object's composition
If a reheating stage is applied to melt undesirable crystals, then the chocolate mass becomes highly liquid, but extensive energy consumption is required and the production line complexity increases
Solution Approach 1:
The system changes temperature parameters across different stages to achieve crystal transformation without reheating. The cooling stage operates at lower temperatures to prevent unwanted crystal formation, while the crystallization stage uses controlled temperature maintenance to promote βV-crystal formation directly, eliminating the need for subsequent reheating to melt unstable crystals.
Solution Approach 2:
Instead of allowing unstable crystals to form and then requiring energy-intensive reheating to melt them, the system converts the potential harm into benefit by using controlled cooling to prevent their formation in the first place. The cooling process itself becomes the mechanism for achieving stable crystal structure, transforming what would be a harmful intermediate state into a beneficial direct pathway to the desired final state.
3Productivity
If the cooling stage uses cold surfaces to cool the chocolate mass effectively, then the cooling efficiency is improved, but the formation of unstable crystals increases
Solution Approach 1:
The cooling and crystallization processes are segmented into distinct stages with different temperature zones. The cooling stage uses cold surfaces for efficient heat removal without prolonged exposure that would cause unstable crystal formation. The crystallization stage then provides controlled conditions for stable βV-crystal development, separating the functions of rapid cooling and controlled crystallization.
Solution Approach 2:
Different regions of the system have different temperature characteristics optimized for their specific function. The cooling stage surfaces are maintained at lower temperatures for efficient heat exchange, while the crystallization stage provides a controlled temperature environment suitable for βV-crystal formation. This local quality differentiation allows each stage to optimize its performance without compromising the other.
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
The process achieves a tempered chocolate mass with desirable βV-crystals and high viscosity, enabling direct extrusion and eliminating the need for cooling tunnels, reducing cocoa butter content, and simplifying the production line by integrating extrusion directly after crystallization, resulting in energy savings and improved product quality.
Implementation Method 1
heated chocolate mass with crystal-free cocoa-butter is pumped as a complete stream through a cooling stage... simultaneously cooled by a row of intermediary, plate-like streams of cooling water
Implementation Method 2
cooled by passage through the cooling stage to a temperature which is below the βV-crystal creation temperature
Implementation Method 3
subjected to intensive homogenous mixing and shear passing through the crystallization stage as planetary mixers accomplish a circular path
Implementation Method 4
subjected to intensive homogenous mixing and shear passing through the crystallization stage... maintaining the chocolate mass temperature essentially constant
Implementation Method 5
maintaining the chocolate mass temperature essentially constant within a few tenth of a degree Celcius... precise temperature control to prevent crystal formation in the cooling stage
Implementation Method 6
an extruder device with at least one orifice through which the continuously tempered chocolate mass is extruded as an extrudate
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
Process and chocolate articles production line (1) for continuous production of chocolate articles (8). In a storage tank (2) a supply of cocoa butter-containing chocolate mass is heated so that the cocoa-butter is crystal-free. The chocolate mass is cooled by passage through a plate-heat exchanger (11) to a temperature which is below 26°C and above 23°C depending of the particular chocolate mass, and which temperature is below the Beta V-crystal-creation temperature for the particular mass. Then, the chocolate mass is subjected to intensive homogenous mixing and shear passing through the crystallization stage (12) as planetary mixers accomplish a circular path in the chambers simultaneously being rotated in an orbital rotation around their own axis of rotation. The chocolate mass is cooled simultaneously in the crystallization stage (12) by cooling water temperatures between 20°C and 25°C maintaining the chocolate mass temperature essentially constant within a few tenth of a degree Celcius as the chocolate mass is subjected to the planetary mixers for a time period of between 100 and 250 seconds being sufficient to remove the latent heat produced as the Beta V crystals are created. The tempered chocolate mass is then provided with a high viscosity so that it can be extruded.