Integrierte Vermeidung und Verminderung der Umweltverschmutzung

Chapter 2
Batters are typically deposited into oil sprayed trays or continuous sheets for products such as
Swiss rolls. After baking, the cakes are removed from the tins and cooled. The empty tins are
cleaned, rinsed, dried and cooled.
2.2.11.3 Cocoa
Drinking cocoa typically consists of cocoa powder, vanillin, cinnamon, salt, cassia and other
powdered spices. Raw beans are received and subjected to a series of washing operations to
remove extraneous matter such as fibre, stones, grit, metal, bean clusters and immature beans.
The latter two materials may be used for the manufacture of cocoa butter. The beans are roasted.
Roasting conditions vary depending on the equipment and the desired product, but are typically
in the range of 100 to 140 °C for 4 to 6 minutes. Whole beans or the separated nibs may be
roasted.
Winnowing is the separation of the outer shell of the bean from the edible nibs and typically
consists of cracking the roasted bean between rollers, followed by air classification to remove
the shell fragments. The nibs are ground to produce a cocoa liquor whose particle size is further
reduced by grinding mills, which are water-cooled. The particle size is important for the
manufacture of chocolate drink but less important for chocolate since this requires some further
refining. The liquor or nibs from roasted or unroasted beans are likely to be subjected to a
process known as alkalisation which increases the dispensability of cocoa powder in milk or
water when used in drinks. It is also used to modify the colour of the cocoa. Only permitted
acids, alkalis and emulsifiers may be used for this process.
Cocoa powder is produced by the hydraulic pressing of cocoa liquor to express cocoa butter and
to reduce the fat content of the press cake to the desired level. The expressed cocoa butter is
used in the manufacture of chocolate. The press cake is pulverised to produce a cocoa powder.
The final product is then packaged.
2.2.11.4 Chocolate
The basic ingredients for the manufacture of chocolate include cocoa liquor, sugar, other
sweeteners, cocoa butter, butter fat, milk powder, milk crumb and emulsifiers. The basic
operations involved in chocolate production are the preparation and mixing of ingredients,
refining and conching. Conching involves agitating the refined material to induce desirable
physical changes in the final product and to improve the flavour. Chocolate production has
traditionally been undertaken in a device called a melangeur, which accommodates all of the
steps involved. Melangeurs are, however, being increasingly replaced by large specialist
machines.
The refining stage in the manufacture of chocolate is intended to reduce the size of the particles
of cocoa solids in the mix, thus ensuring that the mixture has a smooth consistency. This is
achieved by passing the mixture through vertically mounted rollers which need to be water
cooled to prevent distortions arising from frictional heating. A number of systems are available
for conching, which is a specialised activity inducing complex changes in the chocolate.
Processing milk chocolate in a traditional batch conch takes in excess of a day, whilst modern,
continuous systems achieve the same result in around 4 hours. Finished chocolate is typically
stored in bulk and must be tempered through a cooling and warming cycle before final use.
Chocolate products may be produced by casting the chocolate into moulds, followed by cooling
and demoulding. Such methods may be used to produce solid chocolate blocks or shells, which
may be hollow or filled with a confectionery such as fondant. Alternatively, liquid chocolate
may be used to coat confectionery using units known as enrobers.
100 January 2006 RHC/EIPPCB/FDM_BREF_FINAL