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Changemakers

Chocolate Conches

conching

Conching

You can’t buy happiness, but you can buy chocolate; that’s basically the same thing. We were not surprised to discover that chocolate - to be specific, cocoa beans – was so valuable that it was used as a currency in Mayan times. When making chocolate, cocoa beans need to be dried, fermented, and roasted before using chocolate making equipment to turn them into your favorite chocolate product.

Chocolate

<span style="font-weight: 400">Cocoa production and the cocoa industry uses industrial processing technology to process and manufacture high quality cocoa products in many different forms. Did you know that cacao cultivation goes back centuries - to be specific, about 5300 years? </span><span style="font-weight: 400">This plant, with its long history, is also known for its versatile usage. From </span><span style="font-weight: 400">cocoa nips to cocoa butter, cocoa becomes a base to produce multiple products, ranging from food products to cosmetics. As you may already know, chocolate products are all made from cocoa as well. Hence, depending on what you intend to produce as the end product, as well as your recipe, your cocoa processing equipment line may change.</span>

Cocoa

Conching is a critical step in the manufacturing of chocolate. In this phase, your chocolate mix is agitated and superficially scraped by a conch, allowing the cocoa butter to separate amalgamated particles and distribute your cocoa butter more evenly. The heat generated by the process volatilizes acids improving the texture and aroma of the finished product. Early machines used vessels in the shape of a conch shell, giving the equipment its name.

Batch

Industrial

In the chocolate manufacturing industry, the challenge of integrating mixing, refining, and conching processes often arises. This includes achieving the correct texture and flavor in a single, consolidated process, and managing moisture and fineness consistency for a high-quality end product.
<h2>Combine mixing, refining, and conching processes</h2>
The MacIntyre Refiner/Conche by Hamburg Dresdner Maschinenfabriken GmbH is an all-in-one system that performs the functions of a pre-mixer, refiner, and conche. It is available in three versions: Duplex refiner/conches with 3000 kg & 5000 kg capacities, Universal refiner/conches with 500 kg to 3000 kg capacities, and a Laboratory refiner/conche with a batch size of 45 kg. The universal system is ideal for processing dry and low-fat (>24%) products, making it perfect for 'free-from' recipes or formulations with sugar substitutes. Distinguished by its minimal labor requirements and unmatched ease of operation, it efficiently reduces moisture to less than 0.5% if necessary and offers an adjustable fineness range down to 18 µm. The Duplex version features a longer cylinder and double spider wheel arrangement, enhancing cooling efficiency and thermal conductivity, which results in shorter cycle times and a larger surface area for the removal of volatiles, acidity, and moisture. Key applications include refining cocoa nibs to cocoa liquor and mixing it with additional ingredients such as sugar and milk powder, followed by refining the pre-mix to the desired final fineness and developing the finest flavors during the conching phase.

Chocolate refiner and conche solution

Industrial cooling equipment varies according to the consistency and temperature conversion demands the material you are handling, but the process typically involves heat exchange treatment as your products are conveyed through a cooling chamber equipped with extraction fans or circulating water. Temperature control is a crucial aspect of your commercial production and cooling systems are applied to a range of industries.

Cooling

Industrial mixing equipment is used to combine two or more solid, liquid or gaseous segregated ingredients into a homogenous single product. The choice of mixing technology depends largely on the physical state of the ingredients and the desired final product. But the sensitivity of the ingredients, the process temperature, and pressure requirements are also critical factors. All these parameters result in a wide range of industrial mixers.

Mixing

Purification is the removal of contaminating substances and by-products to increase the level of purity of the desired substance. Considerations for choosing a suitable purification system in the industry, include the physical state of the mixture, the desired product, required level of purity, the type of mixture, heat sensitivity of the product, number of purification steps needed, and the production volume. Industrial purification systems are used for the production of pure water in the food pharmaceutical and biotech industries.

Purification

Refining

solid

In the chocolate manufacturing process, achieving a smooth and refined texture is essential. Conching is a critical step that influences the final flavor and texture of chocolate. Traditional conching, involving long mixing times and precise control of temperature and humidity, demands specialized equipment.
<h2>Conches chocolate in controlled batch processes</h2>
The Batch Conches HBC 3 to 6 by Hamburg Dresdner Maschinenfabriken are specialized for the chocolate making process. These batch conches enable you to mix, refine, and conche the ingredients in one integrated system. Available in capacities of 3 to 6 tonnes, these conches are suitable for both small and large production scales. The double-shaft design ensures thorough mixing and aeration, contributing to the breakdown of particles and smoothening of the chocolate mass. Precise temperature and humidity controls help achieve the desired texture and flavor profile, making these batch conches a reliable choice for high-quality chocolate production.

Batch conche for chocolate making

Aerators are devices used for mixing air (oxygen transfer) with a liquid such as water or oil to form a homogeneous product. Selecting an industrial aeration system involves choosing a suitable mixing head and considering the desired input and output flows, temperature, level of aeration, properties of the liquid phase, and the degree of automation and pressure control. Aerators are used in the food industry for the production of fat-based center masses and crèmes and in the chemical industry for wastewater treatment. When it comes to water treatment, surface aerators are most commonly used.

Aeration

<span style="font-weight: 400">The heating process is a step of raising the temperature of food, pharma, cosmetics, and many other types of products. You may employ different heating solutions for this process, depending on the type of product you intend to manufacture. Selecting the appropriate heater machine for your product is quite important since various products require different ranges of temperatures and different ways of heat transfer using exchangers. Industrial heating equipment varies in two ways - the type of material it can process and the reaction you want to achieve.</span>

Heating

In a laboratory setting, developing and refining the flavor profiles of chocolate, compounds, bread spreads, and coatings is essential before large-scale production. Precise control over moisture content and viscosity is critical for ensuring optimal product quality.
<h2>Conche small batches with precise control</h2>
The CWC 5 by Caotech is a compact laboratory conche designed for handling small batches of chocolate and other similar products. It allows precise control over the conching process, including moisture reduction and viscosity enhancement. With a batch capacity of 5 kg and an installed power of 0.7 kW, this unit is ideal for testing and optimizing recipes before transitioning to full-scale production. It efficiently evaporates volatile acids and moisture, reducing moisture content down to 0.9% or even 0.7% in some cases. The conche's dimensions are 600 x 550 x 735 mm, and it weighs 70 kg, making it easy to integrate into any lab setup. The CWC 5 is known for its low maintenance costs, low energy consumption, and consistent product quality.

Laboratory conching solution for small batches of chocolate

Continuous

When producing high-quality chocolate, achieving optimal conching is vital to improve viscosity, yield, and taste. Traditional methods may not effectively remove volatiles, acids, and moisture, requiring a more advanced solution.
<h2>Enhance chocolate quality with wet conching</h2>
The CWC 1000 from Caotech is designed specifically for wet conching of chocolate and related masses. This unit mixes and homogenizes ingredients while removing volatiles, acids, and moisture to improve the final product’s characteristics. The conching effect is achieved through thin-film evaporation, where a fast-rotating disc sprays the chocolate while pre-heated air blows over it. Capable of processing up to 1,000 kg/h, the CWC 1000 delivers consistent quality with minimal maintenance and energy consumption. The system can be installed on a mixing tank with a circulation system provided by Caotech or the customer.

Wet conching system for chocolate production

Evaporation technology is used to reduce or remove the moisture content of a mixture. Considerations for choosing suitable evaporation equipment include the moisture content in the mixture, the boiling point of the solvent, heat sensitivity of the product, and the amount of material to be processed. Evaporators are used for applications such as obtaining fruit and vegetable concentrates in the food industry, concentrating aromas and herbal extracts in the cosmetics industry, and isolating active ingredients in the pharmaceutical industry.

Evaporation

Homogenization is the process of reducing particle size in mixtures to improve the consistency, uniformity, and stability of the product. The choice of a homogenizer depends on the nature of the product, desired particle size, the physical state of the ingredients, and pressure requirements during the process. Homogenization is widely used in the biotech industry for cell lysis and in the pharmaceutical industry for the emulsification of creams and ointments; it also finds applications in the cosmetics and food industries for improving the consistency and uniformity of various products.

Homogenization

liquid

Producing high-quality chocolate or other fat-based compounds requires precise grinding, consistent mixing, and effective conching. Achieving the right end-product fineness within a limited timeframe is crucial for consistency and quality in confectionery production.
<h2>Mix, grind, and conch simultaneously</h2>
The CHOCOCON 150 by Caotech is a specialized unit combining a horizontal 500L mixer/conch and a vertical low-speed ball mill CAO C150. Designed for the mixing, fine grinding, and conching of chocolate, creams, bread spreads, and fat-based compounds using crystal sugar, this equipment can achieve an end fineness of 22-25 microns in around 3 hours. Its high flexibility and attractive price have made it a favored choice for those in the chocolate processing industry. Recent upgrades include a redesigned mixer opening for faster and easier ingredient loading. Specifications include a batch capacity of 500 kg, an installed power of 24.7 kW, and dimensions of 2600 x 1540 x 2100 mm.

Chocolate processing unit for mixing, grinding, and conching

Grinders use a spinning blade or rotating abrasive elements to reduce the size of various materials. The specifications, RPM and grit of the engineered grinder, will result in various particle sizes. As a result, what you want to make will determine the type of grinder you need. Grinding is used for improving the texture and flow properties of various products and to enhance the flavor of food products such as coffee, spices, sugar, nuts, sesame, poppy seeds, lentils, wheat, and rice. Choosing the right rotational speed, grinding elements, and processing power allow the grinding and shredding of a wide range of materials into coarse or fine powders. Popular types of heavy duty grinders in food processing include angle grinders, bench grinders and meat grinders.

Grinding

In the chocolate production industry, achieving homogeneity and the right rheological properties in chocolate mass can be challenging. Ensuring optimal energy intake while maintaining product quality requires specialized technology.
<h2>Optimize chocolate mass production efficiently</h2>
The Frisse ELK S by Bühler is an efficient and flexible single-shaft conche designed for chocolate mass production. This conche features the ability to adjust energy intake throughout the conching process, which results in shorter cycles and savings in cocoa butter usage. With an energy efficiency improvement of up to 10%, the new drive system eliminates the need for V-belt transmission, thus minimizing maintenance and energy losses. The hygienic design ensures compliance with high food safety standards and enhances accessibility for easier cleaning. Proven technology integrated with innovative features makes the Frisse ELK S a reliable solution for producing high-quality chocolate mass.

Single-shaft conche for chocolate production

Creating high-quality chocolate products requires precise control over texture and flavor developments. Traditional methods often fall short in achieving uniform rheological properties and efficient conching times, leading to inconsistencies that can compromise final product quality.
<h2>Optimize conching time and energy efficiency</h2>
The Frisse DÜC S by Bühler is a double-overthrow conche designed to streamline chocolate production. This conche combines advanced engineering with established conching technology, enabling precise adjustments of texture and taste by efficiently removing unwanted volatiles. It offers significant energy savings of up to 10% due to its innovative drive concept and has a reduced footprint, requiring less floor space. The system's special kneading and shearing actions assure precise control over rheological properties from start to finish. A state-of-the-art hygienic design, along with food-grade materials, ensures compliance with the highest hygiene standards. Additionally, the Frisse DÜC S is compatible with SmartFactory solutions, allowing remote diagnostics, process monitoring, and efficient data management.

Double-overthrow conche for chocolate production

Kneading

Complex processes call for continuous tracking and monitoring systems that help you to keep the manufacturing operation under control. The technology analyzes the components in the production phase for divergence in behavior or changes in conditions. Based on advanced software applications, monitoring platforms make sure that your products satisfy the quality criteria while they are being developed.

Monitoring

Shearing

Conching plays a critical role in the flavor development of chocolates. Laboratory testing and development work require the use of a small conche that allows precise control of process parameters.


<h2>Conche small homogenous batches with precise control</h2>
The Lab Conche from JAF INOX is ideal for small batches and laboratory work on all types of fine chocolate. The special design and a 3hp engine allow clockwise mixing and counter clockwise conching with high shear stress to provide a perfectly homogeneous mass without the use of additives. The lab conche has a 1.2KW electrical heater and a PID temperature controller with a resolution of 0.1'C. The PT-100 sensors allow continuous monitoring of water and product temperatures. The lab conche is fitted with micro-exhaustion for the removal of volatiles. It also allows natural exhaustion via open lid/grill. It has a stainless steel construction and a capacity of 10Kg/batch.

Chocolate conche for small batches and laboratory use

High-quality chocolate requires specialized conching. Precise control of temperature and mixing parameters is necessary to enhance taste and ensure consistent quality.


<h2>Conche high-quality chocolate with precise control</h2>
The longitudinal conche from JAF INOX is designed for applications where flavor development has higher priority over production capacity. The renowned longitudinal design uses a roll for shear force and is ideal for conching chocolate of the highest quality. It is equipped with a PID temperature controller and PT-100 sensors for precise temperature control. The longitudinal conche is fitted with micro-exhaustion for the extraction of undesired volatile acids. It has a stainless steel construction and is available in capacities of 3, 250 and 800Kgs.

Longitudinal chocolate conche

Dry conching reduces the moisture of the chocolate flakes and at the same time removes volatile and undesired flavours. Using a two shaft dry conch will help you reduce the conching time.


<h2>Reduce conching time to 6 hours</h2>
The two-shaft dry conche Typ DRC-2 from Royal Duyvis Wiener is used for chocolate and compound masses. Innovative design that offers a more intensive drying process that has resulted in a reduced conching time to approximately 5 to 6 hours.

The dry conching method reduces the moisture of the chocolate flakes while removing volatiles and undesired flavours. The Two shaft dry conche is specially designed to conche the ground chocolate directly from the refiner without having to add cocoa butter, fat and lecithin up front.

The turning circles of the two large conching rotors overlap in the centre of the conche tank and thus provide a good and permanent exchange of chocolate particles between the rotors.

Two shaft dry conche

Dry conching acts by reducing the moisture of the chocolate flakes and removing volatile and undesired flavours all at once. For lower capacities, satisfying results can be accomplished with a single shaft conche.


<h2>Entry-level dry conching</h2>
The shaft scrapes the surface of the batch with its agitator arm that evenly distributes the chocolate, improving the viscosity of your product due to the addition of shear stress. Particles are thereby polished and evenly distributed resulting in a rich flavour development; without the addition of cocoa butter, fats or lecithin.

Because of the powerful motor of the single shaft dry conche, the single shaft performs dry conching at slow and high-speed pace; however, such process normally requires a considerable amount of time. The time required for liquid conching remains the same.

Single shaft dry conche

For thin film treatment of chocolate, compound, and cocoa masses.


<h2>Saves on time, energy and space</h2>
The Liquid Conche (CLC) from Royal Duyvis Wiener has been specially developed for thin film treatment of chocolate, compound, and cocoa masses. The two main functions of its conching process are: the thermal degasification and the mechanical shearing stress. Both functions are carried out in the reactor in the thinly spread mass layer.

The Continuous Liquid Conche is a standalone unit and therefore easily integrated, making it an excellent choice for those looking to upgrade their chocolate processing lines.

Continuous liquid conche

The conching process is the process of redistributing the fat phase and the substances from the dry cocoa that create flavor. The process is so important to the final texture and flavor of chocolate, manufacturers keep the details of their conching process proprietary.


<h2>Energy efficient conching and vaporizing</h2>
The Batch Liquid Conche TC of Royal Duyvis Wiener is a machine that takes care of the conching chocolate process which consists in mixing and vaporizing to produce a rich chocolate with an excellent taste.

The conche scrapes the surface of the batch with its agitator arm that evenly distributes the chocolate improving the viscosity of your product due to the addition of shear stress. Particles are thereby polished and evenly distributed resulting in a rich flavour development. Combined with an efficient thin film evaporator moisture and off-flavours are removed by blasting hot air through a thin layer of product.

Batch liquid conche

Producing high-quality chocolate, creams, bread spreads, and fat-based compounds requires precise control over mixing, grinding, and conching processes. Issues like ineffective grinding and long processing times often pose significant challenges in achieving the desired fine texture and consistency, particularly when using crystal sugar as an ingredient.
<h2>Combines mixing, fine grinding, and conching</h2>
The CHOCOCON 250 from Caotech is a versatile processing unit designed to address the specific requirements of chocolate and compound production. Combining a horizontal 500L mixer/conch with a vertical low-speed ball mill CAO C250, this system is optimized for mixing, fine grinding, and conching chocolate, creams, bread spreads, and fat-based compounds. With a batch capacity of 500 kg, the unit achieves an end fineness of 22-25 microns within approximately 2 hours when using crystal sugar. The grinding time is further reduced when powdered sugar is used. Enhanced with a redesigned mixer opening for easier ingredient loading, the CHOCOCON 250 offers high flexibility and minimal floor space requirements, without the need for a foundation. The unit's low energy consumption, limited heat development, and low maintenance costs contribute to its popularity in its segment.

Chocolate processing unit for mixing and grinding

Entry level

In the research and development of new chocolate and compound recipes, precision and small-scale testing are crucial. Quality control in laboratories requires a dedicated unit to mix, grind, and conch ingredients efficiently and accurately.
<h2>Mix, grind, and conch in one unit</h2>
The CHOCOCON 100 by Caotech is a compact laboratory batch unit designed for simultaneous mixing, fine grinding, and conching of chocolate, creams, bread spreads, and fat-based compounds using crystal sugar as the base ingredient. This solid and efficient 3-in-1 unit is particularly suitable for laboratories to perform small-scale tests before scaling up production. The CHOCOCON 100 has a batch capacity of 100 kg and achieves end fineness of 22-25 microns within approximately 2 hours when using crystal sugar. Using powdered sugar reduces the grinding time further. It features an installed power of 18.5 kW, weighing 960 kg, and dimensions of 1910 x 970 x 1350 mm. With low maintenance costs, constant product quality, and minimized wear, it is a valuable tool for developing new recipes in a controlled environment.

Laboratory batch chocolate processing unit

Producing high-quality chocolate, creams, and fat-based compounds requires precise control over weighing, mixing, grinding, and conching processes. Inconsistent fineness and quality can impact the final product's texture and taste, posing a challenge for manufacturers.
<h2>Automated chocolate grinding and mixing</h2>
The CAO B3000-CHOC DUO by Caotech is a fully automatic production line designed for batch weighing, mixing, grinding, and conching of chocolate, creams, bread spreads, and fat-based compounds. This system is based on two CAO C3000 ball mills and a Mini Mix weighing/mixing unit. The CAO B3000-CHOC DUO handles batch capacities of up to 1,000 kg, achieving end fineness levels of 22-25 microns in approximately 60 minutes when using crystal sugar. The operational efficiency reaches up to 900 kg/h. It can be equipped with automatic feeding systems for ingredients such as fats, lecithin, vanillin, and other aromas. The reduced grinding time when using powdered sugar and the system’s limited heat development ensures constant product quality with low energy consumption. The compact design requires minimal floor space and no foundation, enhancing its practical usability.

Fully automatic chocolate processing line

Industrial feeding systems allows you to control the flow of solid bulk materials throughout the manufacturing line. After loading your material onto the vibrating hopper, a screw at the base drives it out in uniform doses to the next stage of processing. New feeding technologies are designed to deal with challenges of powders clumping together in the hopper (bridging and ratholing) that interrupt the outflow. Common feeder systems include centrifugal feeders, vibratory feeders as well as elevator, linear and pneumatic feeders.

Feeding

Weighing

In large-scale confectionery manufacturing, achieving consistent product quality while minimizing energy consumption and maintenance costs poses a significant challenge. Efficient, automatic processing lines are necessary to handle tasks from weighing and mixing to conching and fine grinding.
<h2>Automates chocolate and compound processing</h2>
The CAO 4000[3]-CHOC IN-LINE by Caotech is a fully automatic production line designed for chocolate, creams, bread spreads, and fat-based compounds. It features three CAO 4000 low-speed agitated ball mills and the Mini Mix mixing/dosing unit. This line handles PLC-controlled weighing, mixing, conching, and continuous fine grinding, ensuring constant product quality. With a capacity of up to 2,500 kg/h using crystal sugar (1.2 mm) as an ingredient, it boasts low energy consumption and maintenance costs. The line's compact design requires no foundation and minimizes floor space. It also integrates various automatic feeding systems for fats, lecithin, vanillin, and more.

Chocolate processing production line

In modern confectionery production, achieving consistent quality of chocolate, creams, and fat-based compounds is crucial. Traditional methods often demand intensive manual oversight, leading to variability in product output and inefficiencies in time management.
<h2>Automate weighing, mixing, conching, and grinding</h2>
The CAO 3000[2]-CHOC IN-LINE from Caotech is an advanced, fully automatic chocolate processing line designed to streamline the entire production process. This system integrates two CAO 3000 low-speed agitated ball mills alongside a Mini Mix mixing/dosing unit, allowing for precise and continuous fine grinding, conching, and mixing operations under PLC control. The line can manage the processing of various products including chocolate, creams, bread spreads, and fat-based compounds, with a capacity of up to 1,500 kg/h when using crystal sugar (1.2 mm). Moreover, it supports automatic feeding systems for ingredients like fat, lecithin, and vanillin, making it a highly efficient and reliable option for large-scale chocolate production. With an installed power of 163 kW and compact dimensions, the CAO 3000[2]-CHOC IN-LINE is designed to minimize wear, reduce energy consumption, and maintain constant product quality.

Automatic chocolate processing line

<span style="font-weight: 400;">One of the challenges when setting up a small-scale cocoa processing factory is making all of the equipment work together for maximum output. Rather than experimenting and compromising on both quality and capacity, a complete entry-level bean to bar line system can help you begin the production of high-quality cocoa-based products right away, at maximum level of output.</span>


<h2>Initiate production of artisan chocolate with small-scale bean to bar line.</h2>
<span style="font-weight: 400;">This entry-level Bean to Bar system by Nemisto contains a range of different units and is the ideal solution for the complete processing of artisan chocolate. The complete line includes bean roasting, nib and shell separation, mixing and refining, conching by refiner conch, and chocolate tempering units that work seamlessly together to produce a high-quality end product.</span>

<span style="font-weight: 400;">The cacao roaster is capable of processing 5 kilograms per batch at a time while the winnower, or more well known as the bean nibs separator can separate up to 20 kilograms of different-sized beans per hour. On the other hand, the pre-grinder can grind approximately 15 kilograms per hour and turn the cocoa nibs fine to a size of between 50 and 100 microns. The pre-grinder can also be adjusted for better quality output, making the overall capacity of this entry-level bean to bar line up to 15kg per day.</span>

<span style="font-weight: 400;">Finally, the 2 roll refiner and conch allow you to set the temperature in 2 places: the rollers and in the bowl. During this process, the speed of conching in the bowl can be customized to determine the fineness of the end product like cocoa liquor and artisan chocolate.</span>

<span style="font-weight: 400;">All units are predominantly made out of stainless steel, guaranteeing longevity, easy maintenance, and cleaning.</span>

Entry level bean to bar line

Dosing systems are a line of hoppers, feeders, filling machines, and checkweighers that operate in sync to dispense materials accurately. Dosing is an essential feature of the packaging process, whether you’re filling shampoo bottles or tea bags. But dosing equipment is critical for formulations, too, particularly in the pharmaceutical and chemical industries. Imprecise dosing may cause quality degradation in the best-case scenario. In the worst scenario, it creates serious health risks.

Dosing

Enrobing your food products means coating them with additional ingredients such as chocolate, syrup, or sugar. By automating this process you produced homogeneous results and reduce wastage. Items are fed to the enrobing machine to be fully or partially covered. Following this, a blower and an agitator combine to shake any excess coating off the individual products.

Enrobing

The process of forming allows you to shape your products homogeneously. Forming machines are fed the manufactured material in bulk and cut it down to specification, so the process takes place between formulation of the mass and the packaging of the final item.

A special class of this equipment – Form, Fill, and Seal Machines (FFS) – creates bags and pouches from flat material such as plastic sheets, fills them with your designated product, and seals them.

Forming

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

Roasting involves extended exposure to heat in an oven or over a fire. Depending on your end product, roasting equipment makes sure that the raw materials you put in undergo even roast intensity before they are transferred for further processing. Some roasting technologies may also be used for other cooking requirements, including toasting and drying. When thinking about roasting, the idea of roasted coffee comes to mind. However, there are a wide array of food products that go through a roasting process. For example, nuts such as almonds and cashews go through a roasting machine

Roasting

Tempering equipment is most commonly used in manufacturing chocolate products as well as bakery products. However, tempering can also be found in the metals industry for processing alloys. The idea behind the tempering process is to heat two or more items to a certain temperature so that they can be blended together easier. Chocolatiers pass the chocolate through a heating cycle and then a cooling tunnel to give their final products a smooth and glossy finish. Tempering machines automate this process, evenly distributing the crystal structure in melted chocolate across the entire production line. Besides enhancing the look and texture of coatings, denser and consistent crystallization also has the benefit of slowing down fat migration in your chocolate-filled products. A vibrating table is an important component for tempering chocolate. First the chocolate mixture goes through a dispenser into the chocolate mould. After which the vibrating table is used to evenly distribute the mixture in the mould so that there are no air bubbles. Thus, creating a smooth and consistent final product.

Tempering

<span style="font-weight: 400;">In order to produce the finest of chocolate products, you need the cocoa nibs to be grinded and refined into liquor to perfection. Unfortunately, reaching the perfect and finest form of liquor can be difficult for small-scale manufacturers, making the use of a small state of the art unit an integral part in producing an amazing end product.</span>


<h2>Robust cocoa nibs melangeur for fine cocoa liquor</h2>
<span style="font-weight: 400;">Using of modern processing technology, the Melangeur by Nemisto is the perfect companion for cocoa grinding processes. This particular system has everything to grind up to 20 kilograms of cocoa nibs into a very fine finish. After grinding for approximately 12 hours, the chocolate can be conched in the same unit.</span>

<span style="font-weight: 400;">Made out of stainless steel, this 120-kilogram unit is not only elegant, extremely strong, and durable but is also easy to maintain and clean. In addition to the long-lasting material that the entire unit is made out of, the Melangeur is fully backed by a powerful motor and high-quality black granite stone that guarantees for grinding the cocoa nibs into fine liquor under 20 microns. Moreover, the classic titling feature makes it unnecessary to lift the vessel or drum to pour out the finished fine product. </span>

Small capacity chocolate melangeur

The production of high-quality chocolate from the bean can often be out of the reach of small producers, who often have had to rely on using chocolate produced by others to create their own confections. An affordable, small scale bean to bar machine can allow small-scale producers to create handcrafted chocolates to their own recipe, adding significant value to their product by selecting specific beans, including single-origin.


<h2>Compact machine to produce high-quality chocolate directly from cocoa nibs</h2>
The Multiprocess C from Tecno 3 is the first small-scale machine to produce chocolate directly from nibs. The unit combines all the processes for chocolate production in one easy-to-operate unit. Process steps include nib grinding, ingredient mixing, ball milling, conching, tempering, and refrigeration. Ease of use and maintenance is ensured by the lack of any pumps or connection pipes, making cleaning straightforward. The entire machine is constructed of AISI 304 stainless steel for strength, longevity and hygiene.

The bean to bar machine is available with 3 mixer sizes allowing the production of batches of 5kg, 25kg or 50kg of chocolate. As well as high-quality bars of dark, milk or white chocolate, the Multiprocess C can also produce Gianduja chocolate, chocolate spreads, nut pastes, and creamy chocolate fillings, providing even more flexibility to small-scale confectionery producers. Designed to be easy to use by a single operator, the Multiprocess C is fitted with a Siemens touch screen HMI to adjust recipe parameters and to monitor the chocolate production process.

Entry level bean-to-bar machine

Whether it is marmalade or pizza, sauce or hummus, chocolate or fruit puree, most food products undergo a cooking step during their production process. Cooking is nothing more than applying heat to food, but there are different methods to do it. For instance, baking, frying, and roasting involve cooking food without using water, unlike boiling or steaming. Industrial cookers such as vacuum and pressure cookers, industrial fryers, industrial ovens, and industrial roasters focus on specialized applications that meet the different needs of the food industry by helping producers achieve a homogeneous cooking process.

Cooking

<span style="font-weight: 400">The molding process is often included in bakery products. Utilizing molding equipment guarantees a uniform shape, weight, and size. The molding machine first gently flattens the dough mix by going through a sheeter, where a series of rollers press the thin piece of dough. The sheet is then cut into the specified shape and, depending on your final product, may be rolled by using a curling chain. After the molding, other ingredients may be added before the products are conveyed for baking or freezing.</span>

Moulding

Installing a chocolate production line that works efficiently and smoothly can be a daunting task, particularly if different suppliers produce different machines.


<h2>Produce fine chocolate from cocoa beans</h2>
The Bean to bar line from JAF INOX includes all major equipment needed to produce great-tasting chocolate from cocoa beans. It has a capacity of 200Kg per batch and is ideal for chocolate makers looking to improve their production capacity and efficiency.

The bean to bar line includes a 60 kg/H capacity classification machine, cylindrical roaster, cocoa cooler, continuous sieve winnower, and a 30 kg batch knife mill. In addition, a 200 x 500 mm five-roll refiner with chiller, a 100 kg/H automatic feed for the refiner, a 200 kg/H single shaft conche, a flex tempering machine, a flex dropping tool, and a 10 m x 60 cm cooling tunnel are also included.

Chocolate bean to bar line 200kg

Developing new products, producing specialty chocolates, laboratory testing, and in-shop production require chocolate production machinery with a small capacity.


<h2>Convert cocoa beans into fine chocolate bars on a small scale</h2>
The 10Kg bean to bar line from JAF INOX includes all necessary equipment to produce great-tasting chocolate from cocoa beans. It is ideal for small batches, small-scale production, laboratory trials, and chocolate shops looking to create the ultimate experience.

The 10 kg bean to bar line includes a classification table measuring 180 x 80 cm, a 10kg cylindrical roaster, a 10 kg/H five-deck winnower with cyclone, a 10kg batch knife mill, a 120 x200 mm five-roll refiner with chiller, and automatic feed of 30 kg/H. It also includes a 10 kg single shaft conche, an 8 kg compact tempering machine, and a 5 m x 30 cm cooling tunnel with indirect heat exchange.

Chocolate bean to bar line 10kg

To mix and refine cocoa liquor, cocoa powder, sugar, and lecithin, several methods can be used. This can be done through the use of a horizontal ball mill and liquid conching.


<h2>Fine processing of chocolate masses</h2>
The EMA-Choc batch lines have a capacity of up to 250 kg/h, 450 kg/h or 1000 kg/h, depending on which ball mill is used. The innovative approach combines a pre-mixer with ball mill refiners, for intermediate and/or fine grinding results in an efficient and sustainable production process.

Suitable for both crystal and powdered sugar based recipes. The horizontal and conical grinding unit has a high flow rate design which makes it possible for ultra-fine refining below 20 microns (D90). The highly wear-resistant materials guarantee the maximum life span of the grinding tools, less wear and the lowest iron intake to the product.

Batch chocolate line with horizontal ball mill

For mixing and refining cocoa liquor, cocoa powder, sugar, and lecithin, several methods can be utilized, such process can be easily accomplished through the use of horizontal ball mills and liquid conching.


<h2>Fine processing of chocolate masses</h2>
The EMA-Choc 1000 and EMA-Choc 2800 are lines of high performance horizontal conical agitators ball mills for the refining of compound, coatings, creams and bread spreads in continuous process; with a processing time/capacity between 1200 to 3200 Kg/h. The innovative approach combines a pre-mixer with ball mill refiners, for intermediate and/or fine grinding results in an efficient and sustainable production process.

The Continuous chocolate line with horizontal ball mills is suitable for both crystal and powdered sugar based recipes. The horizontal and conical grinding unit has a high-flow rate design which allows to get an ultra-fine refining below 20 microns (D90). The highly wear-resistant materials guarantee the maximum life span of the grinding tools, less wear and the lowest iron intake for the product.

Continuous chocolate line with horizontal ball mills

To mix and refine cocoa liquor, cocoa powder, sugar, and lecithin, several methods can be used. This can be done through the use of vertical ball mills and liquid conching.


<h2>Compact in-house processing of chocolate masses</h2>
The Qchoc-400 is an all-in-one chocolate system. Easy to install and to operate and with a capacity range from 50 up to 400 kg chocolate batches when using basic ingredients. This system, consisting of a pre-mixer, a ball mill and a Thin-Film Evaporator (BLC), is designed for maximum efficiency and durability.

From the mixer, the mass is pumped through the vertical grinding chamber of a Wiener ball mill. When the chocolate has the right fineness, the moisture, volatile amino acids and off-flavors are extracted from the mixture. The product is fed first into a high shear chamber. The shear stress device temporarily reduces the viscosity of the mixture, thereby increasing the efficiency of the film vaporizer.

Batch chocolate machine with vertical ball mill

Achieving a balanced, velvety mouthfeel in chocolate is challenging. Larger particles in chocolate result in a sandy consistency, while too fine a particle makes the end product feel watery. Producing the right chocolate texture at 20-30 microns keeping the ideal Gauss curve requires precise handling of the refining process.


<h2>Continuous chocolate refining</h2>
The P10S-CI Series by Tecno 3 is a high-precision refiner using a proprietary refiner with 10 vertical rolls. Designed with three grinding units, the technology simplifies the large-scale continuous processing of chocolate and chocolate fillings. The feed goes first through a pre-refiner stage before reaching the refiner. After that, the process is finished in the ball-mill section.
Each refining unit reaches a maximum capacity of 750 kg/hour, achieving high outputs in a one-step procedure. The P10S-CI has a compact build, saving on floor space.

Refining plant for chocolate

Chocolate in its liquid form is a versatile confection that can serve as a coating for different desserts. The liquid chocolate-making process utilizes a chocolate coating machine and goes through a number of steps before achieving a fine, high gloss, and sharp look. What makes all of this possible is the process of tempering.

Chocolate coatings

Chocolate fillings

Consumers usually eat chocolate spreads along with bread, or other grain-based items, such as pancakes, biscuits, waffles, and others. Although one particular brand has dominated this market for more than 50 years, there is still a place for new, health-friendly innovations and production ideas using chocolate spread machines.

Chocolate spread

Cocoa butter is the fat product of cocoa liquor. It is an integral part of the chocolate-making process. To make cocoa butter, roast and process cocoa beans with the help of a cocoa butter production machine. After that, it undergoes continuous crushing – forming a rich liquid, known as cocoa liquor. You can finally press the liquid to extract cocoa butter.

Cocoa butter

Long was the time when you could only make dragée chocolate – or, to simplify it, to cover chocolate with a layer of chocolate or sugar and then polish it or not. Now, you can use a chocolate panning machine to offer different types of dragée items. Mind that the process of panning may slightly differ according to the product you are making.

Dragee products

Making ice cream is all about mixing and homogenizing. First you need to blend, pasteurize and standardize your mixture. Then store it in tanks and freeze and aerate the mix until it reached the right consistency. Now you can add fruits, cookies and other solids if you like. In the final step the mix goes through an air blast hardening machine and it's ready to store and ship.

Ice cream

The beginnings of chocolate truffles are a bit like the treat itself, misshapen and dusty. But it is a sign of success when multiple sources claim credit for a recipe. Truffle balls manufacturing equipment today forms can truffles into perfect spheres, but the original deliciousness is left unblemished.

Truffle balls

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