Chocolate Tempering Control for Predicting Viscosity and Temper Level
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Solution Overview
Problem
The tempering process for fat-containing, crystallisable masses like chocolate is complex and difficult to control, leading to batch-to-batch variability and increased wastage, while also being energetically costly due to repeated heating and cooling.
Innovation Solution
A method and temperer system that predict and control the temper level and viscosity of tempered chocolate masses by flowing them through a temperer with a crystallization and reheat stage, using a computer model to relate temperer process parameters to the desired quality parameters, allowing for real-time adjustments to maintain target ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional tempering process is used with repeated heating and cooling, then the desired Form V polymorph can be obtained, but energy consumption increases and batch-to-batch variability occurs
Solution Approach 1:
The system performs preliminary analysis of cocoa butter composition using NMR spectroscopy before the tempering process begins. This advance knowledge allows the control system to pre-adjust tempering parameters (temperature, time, agitation) to match the specific fatty acid profile of each batch, eliminating the need for repeated trial-and-error heating and cooling cycles while ensuring consistent Form V polymorph formation.
Solution Approach 2:
The system continuously monitors tempering progress by analyzing the chocolate mass at intermediate stages using NMR spectroscopy. This real-time feedback allows the control system to adjust tempering parameters dynamically, maintaining optimal conditions for Form V formation while reducing unnecessary heating and cooling cycles, thus lowering energy consumption and improving batch consistency.
2Productivity
If traditional tempering process is used, then polymorph formation can be controlled, but process complexity increases and throughput decreases
Solution Approach 1:
The system replaces complex mechanical monitoring and adjustment mechanisms with NMR spectroscopy-based compositional analysis and automated control algorithms. This substitution simplifies the overall process by using chemical information to directly determine optimal tempering parameters, reducing the need for multiple manual intervention steps and increasing throughput while maintaining polymorph control.
Solution Approach 2:
The system dynamically adjusts tempering parameters (temperature, time, agitation speed) based on the measured fatty acid composition and crystallization behavior of each batch. By optimizing these parameters for each specific composition, the system achieves reliable Form V formation in fewer process cycles, increasing throughput without requiring additional complex equipment.
3Reliability
If compositional variability of cocoa butter is not accounted for, then processing is simpler, but quality consistency deteriorates
Solution Approach 1:
The system performs preliminary NMR spectroscopy analysis of the cocoa butter composition before tempering begins, measuring the fatty acid profile and predicting crystallization behavior. This advance compositional knowledge allows the control system to customize tempering parameters for each batch, ensuring consistent Form V polymorph formation despite natural variability in cocoa butter composition, while the automated nature of the analysis keeps the added complexity manageable.
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 improves batch-to-batch variability and increases throughput by maintaining consistent tempering conditions, enhancing the quality of the chocolate and reducing wastage and energy costs.
Implementation Method 1
cooling the melted chocolate mass very slowly, so as to initiate nucleation and growth of predominantly Form V polymorph crystals
Implementation Method 2
reheating the cooled, recrystallised chocolate mass to below the melting point of the Form V polymorph, so as to melt the undesirable Forms I to IV
Data Source
AI summary
A method of predicting a temper level and/or a viscosity of a tempered mass, provided by tempering of a fat-containing, crystallisable mass, for example a chocolate mass, by flowing the mass successively through a temperer comprising an inlet, a crystallization stage to form crystals therein and a reheat stage to melt unstable crystals formed therein, is described. The method is implemented, at least in part, by a computer including a processor and a memory. The method comprises predicting the temper level and/or the viscosity of the tempered mass using a model, wherein the model relates the temper level and/or the viscosity of the tempered mass to one or more temperer process parameters. A method of controlling tempering and a temperer are also described.