Chocolate Viscosity Control via Post-Conching Fat Calculation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Chocolate production processes face challenges in maintaining optimal viscosity levels, leading to excessive use of costly viscosity-reducing substances and increased production time, as existing methods struggle to accurately predict the required fat content to meet viscosity specifications.

Innovation Solution

A method involving measuring the viscosity of the conched cocoa mass, calculating the necessary viscosity-reducing substance based on reference data, and adding it subsequently during conching to adjust viscosity levels, while refining reference models using actual batch data to minimize errors and optimize fat content usage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If more viscosity-reducing substance is added at mixing to ensure maximum viscosity specification is met, then viscosity specification is consistently met, but quantity of viscosity-reducing substance exceeds minimum required quantity

Engineering Contradiction:

Improveviscosity specification complianceVSAvoidwaste of viscosity-reducing substance

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent applies preliminary action by measuring viscosity after conching and calculating the required viscosity-reducing substance addition in advance, before the final product is formed. This allows precise determination of the minimum needed quantity, avoiding both over-addition and under-addition that would require reprocessing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback by measuring the actual viscosity of the conched cocoa mass and using this measurement to calculate the precise quantity of viscosity-reducing substance needed. This closed-loop approach ensures the minimum required quantity is added to meet specifications without excess, eliminating waste while maintaining compliance.

Inventive Principle:

Principle #23Feedback

2Loss of substance

If quantity of viscosity-reducing substance is limited in initial ingredients to avoid waste, then waste is reduced, but additional conching time is required to meet viscosity threshold

Engineering Contradiction:

Improvewaste of viscosity-reducing substanceVSAvoidadditional conching time

Core Design Contradiction:

Loss of substanceVSLoss of time

Solution Approach 1:

The patent performs viscosity measurement and calculation of required viscosity-reducing substance addition after conching but before final product formation. This preliminary assessment allows the process to avoid unnecessary additional conching time by precisely determining the exact quantity needed, thus eliminating both waste and extended processing time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system enables self-service by using the measured viscosity data to automatically calculate and determine the precise quantity of viscosity-reducing substance required, allowing the process to self-adjust without requiring extended conching time or manual intervention to compensate for initial estimation errors.

Inventive Principle:

Principle #25Self-service

3Loss of substance

If viscosity measurement and calculation is performed after conching, then precise control of viscosity is achieved and waste is reduced, but additional process step is added

Engineering Contradiction:

Improvewaste of viscosity-reducing substanceVSAvoidprocess steps

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent integrates feedback by measuring viscosity after conching and using this information to calculate the precise quantity of viscosity-reducing substance needed. This feedback mechanism eliminates waste by ensuring the minimum required quantity is added, and the calculation can be performed using existing process data without requiring complex additional equipment.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent uses viscosity measurement and calculation as an intermediary step between conching and final product formation. This intermediary assessment allows precise determination of the required viscosity-reducing substance quantity, bridging the gap between conching output and final product specifications without adding significant complexity to the overall process flow.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 allows for precise control of viscosity, reducing waste and production time by accurately determining the required fat content, thereby minimizing the use of expensive viscosity-reducing substances and ensuring consistent product quality.

Implementation Method 1

measuring viscosity of the conched cocoa mass

Methodology Applied

Scientific EffectViscometer measurement: Viscometer

Data Source

PatentUS20210112824A1Process of chocolate production

Publication Date: 2021.04.22 LECLERC JEAN PHILIPPE

AI summary

The process can include mixing ingredients into a cocoa mass, conching the cocoa mass, and, subsequently to conching, measuring viscosity of the conched cocoa mass, contingent upon said viscosity being higher than a target viscosity value, calculating, based on the measured viscosity and reference data representing a reference model of viscosity vs. viscosity-reducing substance content for the chocolate to be produced, a quantity of cocoa butter to be added to the cocoa mass, and adding the quantity of cocoa butter to be added to the cocoa mass.