A major confectionery manufacturer based in the Gulf states needed to re-evaluate their chocolate making process to reduce fat usage and consequently enhance profitability.
It was essential not to affect the quality, viscosity or process performance of their high quality chocolate.
It was also important that the manufacturing operations were not interrupted by the tests so it was important that the team was able to understand and anticipate process problems before they became critical
Because travel was restricted, I developed a highly detailed test programme for the company as well as extensive background information to help them monitor and control the tests and to understand the reasons for various tests, outcomes and decision points.
The programme included
- Investigating ingredient composition and specification and the effects of the process on the ingredients and plant performance
- Investigating the effect of varying fat additions at various stages of the process as well as evaluating types of emulsifier and the effect of varying the time and amount of emulsifier added.
- Varying temperature, mixing times and energy inputs and profiles for the mixing, pre refining, refining and conching processes
- Varying particle size while critically examining the effect on product quality
The client was able to analyse and optimise the entire chocolate making process and significantly reduce fat usage without affecting quality or functionality.
In addition they now have a better understanding of the physical and chemical changes during the process and the implications of those changes on process performance, product quality and fat usage.