Chocolate and Compound Production

NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
Chocolate and Compound Production:
A Revolutionary Solution
Chris Esterly
Confectionery Focus Leader
PACK EXPO 2014
The NETZSCH Group
Global Presence
Erich NETZSCH
GmbH & Co. Holding KG
Analyzing & Testing
Grinding & Dispersing
Pumps
The program comprises
thermoanalytical equipment and
devices to determinate
thermophysical characteristics
Comprehensive machine
program for wet and dry
grinding, mixing, dispersing,
deaeration and classificaition of
different industrial sectors
Comprehensive pump program
for industrial conveing tasks –
Manufacturer of worldwide
known NEMO® cavity pumps
§  Founding:
§  Turnover:
§  Staff:
§  Locations:
1873 by Thomas and Christian Netzsch in Selb
approx. 450 Mio. €
approx. 3000 worldwide therefrom approx. 1000 in
Germany
127 worldwide in 24 countries
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
NETZSCH
(Shanghai) Machinery
and Instruments Co., Ltd.
Anting, Shanghai, China
NETZSCH
Fine Particle Technology, LLC.
Exton, PA, USA
NETZSCH
Indústria e Comércio de
Equipamentos de Moagem Ltda.
Pomerode – SC, Brazil
NETZSCH
España, S.A.
Terrassa/Barcelona
Spain
NETZSCH
Mastermix Ltd.
Lichfield,
Great Britain
NETZSCH
CONDUX Mahltechnik GmbH
Hanau, Germany
ZAO NETZSCH Tula
Tula, Russia
NETZSCH
Feinmahltechnik GmbH
Selb, Germany
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
1.  Cocoa and Chocolate Mass Production
2.  Conventional Process
3.  NETZSCH Process
4.  Comparison Conventional x NETZSCH Process
5.  Conching Process
6.  Dry Conching – the advantage
7.  Refining
8.  Plants
1. Cocoa and Chocolate Mass Production
Cocoa Mass Production
Cocoa
Beans
Pre Cleaning
Cocoa
Mass
Sterilizing
Roasting
Crystal
Sugar
Milk
Powder
Cocoa
Butter
Break,
Cleaning
Cocoa Nibs
Dosing
Alkalinization
(optional)
Mixing
Pre Grinding
Fine Grinding
Cocoa
Mass
Heating to
Press
Fine Grinding
Dry Conching
Pressing
Cocoa Butter
Breaking
Filtering
Grinding
Dehodorizing
Wet Concihing
Sieving
Chocolate
Mass
Conditioning
Packing
Cocoa
Powder
Pre Grinding
Cocoa
Butter
Chocolate Mass Production
1. Cocoa and Chocolate Mass Production
Cocoa Mass
Crystal Sugar
Milk Powder
Dosing
Mixing
Pre Grinding
Fine Grinding
Dry Conching
Wet Conching
Sieving
Chocolate
Mass
Cocoa Butter
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
1.  Cocoa and Chocolate Mass Production
2.  Conventional Process
3.  NETZSCH Process
4.  Comparison Conventional x NETZSCH Process
5.  Conching Process
6.  Dry Conching – the advantage
7.  Refining
8.  Plants
2. Chocolate Mass Production
Conventional Process
Classical Process
Cocoa
Mass
Crystal
Sugar
Milk
Powder
Dosing
Mixing
Pre Grinding
Refining
Conching
Liquefyiing
Sieving
Chocolate
Mass
Cocoa
Butter
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
1.  Cocoa and Chocolate Mass Production
2.  Conventional Process
3.  NETZSCH Process
4.  Comparison Conventional x NETZSCH Process
5.  Conching Process
6.  Dry Conching – the advantage
7.  Refining
8.  Plants
3. Complete Process Chocolate Production
The NETZSCH Process
Process
Cocoa
Mass
Crystal
Sugar
Milk
Powder
Dosing
Mixing
Dry
Conching
Liquefying
Pre Grinding
Fine
Grinding
Chocolate
Mass
Cocoa
Butter
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
1.  Cocoa and Chocolate Mass Production
2.  Conventional Process
3.  NETZSCH Process
4.  Comparison Conventional x NETZSCH Process
5.  Conching Process
6.  Dry Conching – the advantage
7.  Refining
8.  Plants
4. Comparison Conventional x NETZSCH
Economical Efficiency
Classical Process
Min 22-25% Fat
Max 200 µm 100-­‐120 kWh/Ton
8-12 hours process
100-150 kWh/Ton
Refining 100-120 kWh/Ton
Conching 100-150 kWh/Ton
Cycle Time ~8-12 hours
250 m² for 48 Tons/Day
250-300 kWh/Ton
Continuous linked process
Process
2-4 hours process
60-80 kWh/Ton
Min 8-18% Fat
Max 2000 µm
20-40 kWh/Ton
2-6 hours process
Refining 60-80 kWh/Ton
Conching 20-40 kWh/Ton
Cycle Time 3-6 hours
120 m² for 48 Tons/Day
150 kWh/Ton
Simultaneous process
4. Comparison Conventional x NETZSCH
Economical Efficiency (Plant for 48 Tons/day)
Conventional System
Feeding and transporting to silo for crystal sugar dosing
Feeding and transporting system to powdered milk silo
H
kW
P
kW
Crystal sugar feeding hopper with feeding screw
Powdered milk feeding hopper with feeding screw
0,375
0,375
7,5
Lifting system for crystal sugar
1,125
Powdered Milk dosing silo
7,5
Lifting system for powdered milk
1,125
Mixer with weighing system for 1500 kg/batch
37,5
Crystal sugar transporting screw
1,125
Feeding belt for the prerefiner system (2 roller)
1,125
Powdered milk transporting screw
1,125
Prerefiner 2 Roll (1000mm)
52,5
Crystal sugar silo with agitator arm
Prerefiner discharging screws
2,25
Prerefined sugar extracting screw
Feeding belt for the 5 Roll refiners
1,125
Powdered milk silo
5,625
1800 mm Refiner - 5 Roll
93,75
Powdered milk extracting screw
1,125
1800 mm Refiner - 5 Roll
93,75
Feeding screw for the Conche
Refiners discharging belts
6,75
U-6000 Conche for 6 Tons/batch (1)
Crystal sugar dosing silo
3
3
NETZSCH ChocoEasy System
Conche (1) 6 Ton
101,25
Conche (1) 6 Ton
101,25
Conche (1) 6 Ton
101,25
Conche (4) 6 Ton
101,25
9
1,5
1,5
62
Discharging pump
5,5
Circulation tank 6 tons
3,75
U-6000 Conche for 6 Tons/batch (2)
62
Discharging pump
5,5
Circulation tank 6 tons
3,75
Pump for Conche discharge (Conche 1)
2,25
Pump for Conche discharge (Conche 2)
2,25
Refiner - Bead Mill LME300K
Pump for Conche discharge (Conche 3)
2,25
Electric and Operating Panel
3
Pump for Conche discharge (Conche 4)
2,25
Refiner - Bead Mill LME300K
110
3
Electric and Operating Panel
Electric and Operating Panel
726,8
110
3
389,5
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
1.  Cocoa and Chocolate Mass Production
2.  Conventional Process
3.  NETZSCH Process
4.  Comparison Conventional x NETZSCH Process
5.  Conching Process
6.  Dry Conching – the advantage
7.  Refining
8.  Plants
5. Conching Process
General Aspects
Conching Process
Flavour and Rheology Development
Effects
• 
Flavour and Aroma transference and diffusion between cocoa,
sugar and milk
• 
Chemical reaction, f. ex. Maillard reaction
• 
Reduction of Moisture carried in by cocoa mass and milk
powder, from approx. 2% to below 1,0 % preferably below 0,6%
• 
Reduction of acidity, mainly acetic acid resulting from cocoa
fermentation, through evaporation and stripping effect with water
carriage
5. NETZSCH Conching Process
Conching Process
Flavour and Rheology Development
Effects
• 
Flavour transference cocoa, sugar and milk
• 
Chemical reactions, f. ex. Maillard reaction
• 
Reduction of Moisture from 2-3% to < 1,0 %
• 
Reduction of acidity,
• 
Stripping effect with water carriage
• 
Oxidation of cocoa tannins, less adstringency
Conch Heating
Mixing, shear
Hot air injection
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
1.  Cocoa and Chocolate Mass Production
2.  Conventional Process
3.  NETZSCH Process
4.  Comparison Conventional x NETZSCH Process
5.  Conching Process
6.  Dry Conching – the advantage
7.  Refining
8.  Plants
6. Dry Conching
The advantage
Picture: View into a CHOCOEASY® Conch
Nozzle for filtered, preheated air
Shaft for mixing,
shearing, contacts
between particle
surfaces
• 
Required fat content for dry conching only 17-18 %!
(less than in traditional process, normally 22-24%)
• 
Fast flavor treatment (save production time)
• 
No high shear forces required in this process step (save of energy)
6. Dry Conching
The advantage
Evolution of Chocolate Conching in Time & Efficiency
>30% Fat
48-72 Hours
22-25% Fat
8-12 Hours
8-18% Fat
3-6 Hours
6. Dry Conching
The advantage
CE 6000 – Dry conching of milk chocolate
• 
Low maintenance costs
• 
Minimal manpower required
• 
Saving of up to 30 % of energy costs
• 
Enclosed system
• 
Easy operation
• 
Change of formulation is possible
at any time
• 
Production of dark, milk, white or nougat chocolate is possible
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
1.  Cocoa and Chocolate Mass Production
2.  Conventional Process
3.  NETZSCH Process
4.  Comparison Conventional x NETZSCH Process
5.  Conching Process
6.  Dry Conching – the advantage
7.  Refining
8.  Plants
7. Refining „by NETZSCH“
Development of Agitator Bead Mills
1896
1958
1974
1985 / 1995
1963
2004
7. NETZSCH Refining
Development of Agitator Bead Mills
Disadvantages of conventional bead mills:
Netzsch-Chocolate Refiner LME
•  Wide particle size distribution because
of limited flow rates
•  Temperature and steel wear problems
(bead compression, big beads!)
•  Less energy input while cooling is not
sufficient (bad distribution in chamber)
A good chocolate refiner...
..... should avoid bead compression!
..... should allow high flow rates
..... should have high cooling efficiency
Comparison NETZSCH LME x 5 Roll Mill
NETZSCH LME Process
Classical 5 Roll Mill
C 
Lower Investment
D 
High Investment
C 
Space Saving
D 
Big Area demand (belts, pre-refining)
C 
Enclosed Process
D 
Open Process (higher risk of contamination)
C 
Easy Cleaning
D 
Higher Cleaning Costs
C 
Easy Maintenance
D 
High Maintenance Costs
C 
Easy refilling of beads
D 
High Costs for Roll reconditioning
C 
Simple Operation
D 
Difficult operation, higher human interference
C 
No need of adjustments
D 
Need periodic adjustments (cylinders)
C 
Can run with different viscosities
D 
Adjustments on case of different recipes
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
1.  Cocoa and Chocolate Mass Production
2.  Conventional Process
3.  NETZSCH Process
4.  Comparison Conventional x NETZSCH Process
5.  Conching Process
6.  Dry Conching – the advantage
7.  Refining
8.  Plants
8. Plants for Chocolate Mass Production
System RUMBA®
8. Plants for Chocolate Mass Production
CE 6000 II
Product:
Milk chocolate
< 20 µm
1 ton / hr
580 to / month
8. Plants for Chocolate Mass Production
2 x CE 6000 II
To produce milk, dark and white chocolate mass,
approx. 120 tons/day – 24 hours/day
Quality: 23 up to 30 µm, measured with digital Micrometer Screw ½ in Oil
8. Plants for Chocolate Mass Production
6 x CE 6000 II
8. Plants for Chocolate Mass Production
System SALSA®
SALSA® 2000
(compact design)
LME 200, Compound Production SALSA® 2000
Capacity (crystal Sugar): approx. 750 kg/h
8. Plants for Chocolate Mass Production
CE 6000 LME500
To produce Premium Compound Mass,
approx. 48 tons/day – 24 hours/day
Quality: 20-22 µm (measured with digital Micrometer Screw ½ in Oil)
NETZSCH – Chocolate Laboratory
Selb, Germany: Trials for Chocolate (White, Milk, Dark), Fillings, Compounds ...
CHOCOEASY® CE 50
Test report
Recipe
development
LME 6
NETZSCH – Chocolate Laboratory
Measurements on Site:
(International Standard)
•  Fineness with Laser-Analyzer
•  Moisture content
•  Viscosity and Yield Value
Particle Analysis
Rheology
NETZSCH – Global Sales and Service
§  Process support and recipe development
§  Commissioning
§  Training on site
§  Germany
§  UK
§  Spain
§  Turkey
§  Russia
§  France
§  USA
§  Mexico
§  Brazil
§  India
§  China
§  Indonesia
§  Singapore
NETZSCH Confectionery
Your Global Partner for modern Confectionery Mass Production
Chris Esterly
NETZCSH Premier Technologies, LLC
125 Pickering Way
Exton, PA 19341
Telephone No.: 610-209-0543
[email protected]
Thank You Very Much for Your Attention