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The quality of chocolate products, in particular their gloss, their texture and their melting behaviour, depends primarily on two processing steps: the precrystallisation of the chocolate mass and the eventual cooling process. Conventionally, the chocolate mass is treated in tempering machines in order to create the desired crystals. At the present laboratory, an alternative technology was invented using a cocoa butter crystal suspension (CBCS) produced in a shear crystalliser for seeding the chocolate mass. There was an interest to compare these different precrystallisation methods, in particular according to rapid cooling. The cooling process of chocolate products is usually very time-consuming and costly and is optimised only on the basis of the developing product temperature. In the present work, investigations were performed concerning both the cocoa butter crystal suspension and the cooling process of differently precrystallised masses (filling, dark and milk chocolate). The CBCS and its development were investigated using NMR, DSC, microscopy and Xray diffraction methods. The crystals had a flake-like morphology. CBCS produced in the two-stage crystalliser (continuous process) contained much smaller crystals than that from the single stage crystalliser (batch-wise process). The melting range of CBCS produced in the two-stage crystalliser was the same as for cocoa butter of form βV whereas the CBCS produced in the single stage crystalliser showed a higher melting range, similar to βVI. The X-ray diffraction pattern of the CBCS from a single stage crystalliser was similar to the pattern of cocoa butter of form βVI, as well. The crystallisation of cocoa butter under shear (in a Searle geometry) was investigated using synchrotron radiation. The development of α and the subsequent transformation to βV was simultaneously observed by rheologic and X-ray diffraction measurements. The cooling process was described by four main characteristics: (1) development of the solidification using needle penetration, (2) development of the contraction measured offline in a rheometer, (3) the detachment process of the product from the mould using an ultrasonic technique and (4) the visual evaluation of the product surface immediately after the production and after some storage time. No significant differences in these four characteristics were observed between tempered and seeded dark and milk chocolate. Large differences occurred only between tempered and seeded filling mass. Only the seeded filling mass showed a typical precrystallised behaviour, whereas tempered filling mass crystallised as the unprecrystallised one. In particular at low cooling rates, the seeded samples showed stronger solidification, higher contraction and a glossy surface which was stable for several months of storage. In contrast, on the surface of the tempered filling mass a layer of crystallised fat developed after a few days of storage.

Solidification and contraction of confectionery systems in rapid cooling processing