Simultaneous Roasting and Comminution of Cocoa Mass

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Solution Overview

Problem

Conventional methods for processing fat- and/or oil-containing materials, such as cocoa, are complex, prone to uneven heat distribution, and result in non-even aroma development, requiring multiple separate processing steps.

Innovation Solution

Simultaneous roasting and comminuting of solid raw materials in the same step, utilizing a liquid matrix to enhance aroma development and efficiently strip off volatile organic compounds and moisture, while reducing particle size.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate roasting and grinding steps are used, then flavor development and particle size reduction are achieved, but processing complexity increases and processing time extends

Engineering Contradiction:

Improveflavor development uniformityVSAvoidprocessing steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines roasting and grinding operations into a single integrated process step, where material is simultaneously heated and size-reduced. This merging eliminates the need for separate roasting and grinding equipment and process steps, thereby reducing processing complexity while maintaining both flavor development and particle size reduction functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The processing system performs multiple functions simultaneously - thermal processing for flavor development and mechanical comminution for particle size reduction - within a single unit or process step. This multi-functionality approach allows one system to accomplish what traditionally required separate specialized equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If conventional separate-step processing is used, then thorough flavor development is achieved, but processing time is extended

Engineering Contradiction:

Improvearoma developmentVSAvoidprocessing time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent implements continuous simultaneous roasting and grinding, where thermal processing and mechanical size reduction occur concurrently without interruption. This continuous dual-action process eliminates the sequential time delay inherent in separate steps, achieving thorough aroma development while significantly reducing total processing time.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The material undergoes preliminary size reduction during the roasting process itself, rather than requiring complete grinding after roasting. This preliminary comminution action during thermal processing increases surface area for flavor development while reducing the subsequent grinding burden, thereby compressing the overall processing timeline.

Inventive Principle:

Principle #10Preliminary action

3Use of energy by moving object

If fluidization-based roasting is used, then heat transfer is improved, but uneven heat distribution and non-even aroma development occur

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidheat distribution uniformity

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The patent applies different processing conditions to different portions of the material stream simultaneously. By combining roasting and grinding in a single step, material experiences localized thermal and mechanical treatment that ensures uniform heat distribution and consistent aroma development across all particles, avoiding the unevenness caused by fluidization-based methods.

Inventive Principle:

Principle #3Local quality

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 significantly reduces processing time and complexity, enhances aroma and flavor profiles, and accelerates downstream processes like conching by up to 50%, with improved aroma diffusion kinetics.

Implementation Method 1

During said step of simultaneous roasting and comminuting, said liquid matrix becomes enriched by aromatic compounds

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

VOC (volatile organic components) and moisture are stripped off from the material more efficiently

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

the diffusion kinetics of the aromatic substances to the amorphous surface is shortened

Methodology Applied

Scientific EffectDiffusion: Diffusion

Data Source

PatentEP4573921A1Method for processing fat- or oil-containing mass

Publication Date: 2025.06.25 BUHLER AG

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AI summary

The present invention is related to a method of processing a material, said material being selected from the group consisting of a solid raw material that upon grinding releases a liquid phase, and a combination of a solid raw material and a liquid matrix, the method comprising roasting and comminuting the solid raw material, characterized in that roasting and comminuting the solid raw material are carried out simultaneously in the same step. The present invention is furthermore related to a plant for carrying out said method, and to a product obtainable by said method.