Final Report Summary - ULTRACHOC (Ultrasound-based tailoring and control by real-time monitoring of the tempering process during chocolate manufacture)
Executive Summary:
ULTRACHOC was a two year applied research project, which commenced in January 2013 and finished in December 2014, and was funded under the “Research for SMEs” programme of the European Commission’s Seventh Framework Programme (FP7).
During the manufacture of chocolate a proper pre-crystallization or tempering process is demanded by the complex polymorphism of cocoa butter in order to obtain a high quality product. Tempering is critical for reducing processing failures and ensuring quality end product. Tempering is a highly complex process involving a series of careful temperature and mechanical energy input (by shear) controlled steps, whereby programmed temperature-shear-time processes are designed to obtain high quality chocolate products. Few solutions exist for controlling the tempering process of chocolate.
The overall goal of the project was to develop an on-line sensor system capable of measuring with precision and in real time the changes in the chocolate melt during tempering; and to control the crystallization of cocoa butter into the most desirable form (form V). The ULTRACHOC technology is based on the combination of the two ultrasound-based technologies that are readily integrated in a chocolate tempering machine i) High Power Ultrasound (HPU) for controlling the fat crystallization during tempering and ii) Ultrasound of low energy (Ultra Sound Doppler Velocimetry coupled with Pressure Drop measurement (UVPPD) for the development of an on-line sensor capable of measuring the temper level of chocolate, avoiding the need of the actual off line measurements. The ULTRACHOC prototype integrates a control and calibration software that enables automated tuning of the tempering process in order to adjust the tempering process to meet the end-user pre-sets.
of chocolate, avoiding the need of the actual off line measurements. The ULTRACHOC prototype integrates a control and calibration software that enables automated tuning of the tempering process in order to adjust the tempering process to meet the end-user pre-sets.
Project Context and Objectives:
Chocolate, a complex suspension, is a luxury food that during consumption evokes a range of stimuli that activate pleasure centres of the human brain. Textural and sensorial characteristics are fundamental to the overall quality and consumer acceptance of chocolate. Like many confectionery products, chocolate contains cocoa butter, which is obtained by pressing ground cocoa beans. It is a primary ingredient that allows chocolate to melt and flow easily in the mouth and this greatly influences the texture of the chocolate. One key element of the texture is that chocolate remains essentially a semi-solid at room temperature, but melts readily in the mouth at the normal body temperature of 37ºC. The physical and textural properties of this food depend on the microstructure formed during the crystallization of liquid fat and are affected by the processing and storage conditions. Fats, in general, feature a complex polymorphism, which is strongly influenced by its composition and heat, mass, and momentum transfer during crystallization.
Cocoa butter can crystalize into six polymorphic forms (I-VI) but only one, named beta crystal or Form V, is the most desirable form in chocolate, giving a glossy appearance, pleasant texture, good snap, contraction, good demoulding properties, stable shelf-life and resistance to bloom. Polymorphism of cocoa butter is an important material characteristic in chocolate manufacturing as it is directly linked to product quality and processing performance.
Due to the complex nature of polymorphism of cocoa butter, a process known as tempering is required during chocolate manufacture. Tempering is a complex thermal treatment of the fat phase of chocolate to form the proper type, amount and size of fat crystals. The key goal in conventional tempering processes is to achieve 1-2% solid fat content (SFC) in the tempering machine at a temperature where mostly Form V cocoa butter crystals can survive. To this end, in order to ensure the formation of crystals of the right polymorph form, good tempering involves a series of careful temperature and mechanical energy input (by shear) controlled steps, whereby programmed temperature-shear-time processes are designed to pre-crystallize chocolate in the correct manner.
The overall goal of the project was to develop a on-line sensor system capable of measuring with precision and in real time the solid fat content (SFC) of the chocolate and changes in the chocolate melt during tempering; and to control the crystallization of cocoa butter into the most desirable form (form V) by using ultrasound of low frequency. To this end the ULTRACHOC system combines in a unique system two methods for controlling and monitoring the tempering process, based on the one hand, on the use of high power ultrasound (HPU) to control the fat crystal size and polymorph distribution in the melt; and on the other hand, ultrasound of low energy for the development of an on-line sensor capable of measuring the SFC (Ultrasound Doppler-based Velocity Profile and Pressure Drop technique and Ultrasound Attenuation technique, UVPPD and USA).
The specific objectives can be summarized as follows:
• To use the results of a “bottom-up” research approach to gain understanding of the industrial needs and define the specifications of the ULTRACHOC system.
• To validate the use of high power ultrasounds (HPU) for improving the pre-crystalization of chocolate at laboratory level
• To validate at laboratory scale the potential of the UVPPD-USA technology for monitoring on- line the rheological properties of chocolate during tempering.
• To develop models for predicting resulting structure density in chocolate products and depending textural and stability properties.
• To gain an understanding of both technologies in lab-scale system systems in order to conceptualise and build the best industry applied prototype that integrates both technologies for monitoring and controlling the tempering process.
• To carry out calibrations and preliminary test to ensure the proper functioning of the system and its control unit.
• To install the prototype in industry to validate its performance in the field, comparing it to conventional tempering methods.
• To carry out quality analysis of chocolate samples resulting from industrial trials
• To make the necessary modifications and improvements to optimise the prototype and define future development work.
• To efficiently manage all knowledge-related matters arising from the project and to adequately protect project IPR embedded in the dissemination and use actions.
• To facilitate the uptake of the ULTRACHOC results by the participating SMEs, as well as by a wider audience, by carrying out demonstration activities.
• To draft a plan for the use and dissemination of the project results, as well as to plan activities for the future exploitation of the foreground.
The overriding goal of this project is to ensure that the pre-competitive ULTRACHOC prototype resulting from this project fulfills the threshold requirements to ensure its further development post-project into a fully industrial system that is taken to market, where its beneficial impact will be felt at European level.
Project Results:
The first target of the project focused on understanding the technological needs of European chocolate producers, as well as market needs and perceptions in terms of product quality, new technologies, etc. To this end, a questionnaire-based on-line survey directed to chocolate producers, and equipment providers was implemented as part of WP1. The gained in-sight was further broadened by desk research on market and socioeconomic information, literature reviews and patent searches on the technology at hand, and a number of on-site visits and in-depth consultations. With this information, both the industry and research partners worked closely to define the industrial needs of the proposed ULTRACHOC system.
A laboratory test rig allowing high power ultrasound (HPU) application at different temperatures, time and high ultrasound power levels, was set-up at SIK The potential of using HPU as a tool to improve the pre-crystallization process, i.e. the nucleation and crystal growth of polymorphic form beta-V fat crystals, in chocolate was thoroughly investigated. In order to extract as much knowledge possible on the effects of HPU on chocolate pre-crystallization process, experiments were conducted on both batch and continuous systems. Also, as the composition differs significantly between dark, white and milk chocolate, each chocolate sort was investigated individually with respect to optimal parameters during HPU. During batch trials each chocolate sort was evaluated with respect to penetration depth of acoustic energy, temperature distribution during HPU and fat crystal formation. Strength of the HPU treatment (generated power output), treatment time (continuous vs. pulses), static vs. dynamic conditions (shear vs. no shear), sample temperature and frequency were investigated parameters. During the continuous experiments, the parameters derived from the batch wise investigations were tested and further adapted in dark and white chocolate. The optimal conditions for HPU treatment for enhancing the formation of beta V crystals were identified in terms of frequency, amplitude, start temperature and duration of the treatment, providing the operating conditions for the scale up system.
In parallel, ETH started the experimental work with UVP-PD and USA with the aim to determine optimum device and measuring conditions to monitor the tempering of chocolate by a contactless, non-invasive on-line measuring. This objective was be achieved through a cascading approach starting with the design and build up of test stand, performing tests and measurements, relating online measurements to off-line analysis and finally deriving correlations between on-line measurement and off-line analysis allowing to characterize the quality of the pre-crystallization/tempering process. The experiments carried out clearly demonstrated that it is possible to measure viscosity of chocolate by means of UVP-PD. Furthermore it was demonstrated that the changes generated by temperature change or by crystallization of fat can be detected and measured by UVP-PD. Measurements of Time of Flight and attenuation also showed a clear influence of the temperature on the measured signals whereas different degrees of crystallization indicated a certain influence on TOF and attenuation. A major challenge of the given test set up was to achieve and maintain steady state conditions. Within the measuring time it was possible to achieve “steady state” but it was difficult to reproduce these conditions. Nevertheless, it was possible to derive Process-Structure-Properties functions that serve as a basis to establish predictive models. To accomplish this objective tests with one type of milk chocolate were performed applying different temperature conditions and different degree of crystallization in order to analyse the relationship between physical properties of the chocolate and the measured signals obtained by means of UVP-PD. Based on these measurements mathematical correlations were established that can be used to derive the degree of crystallization from the on line measured data.
In parallel with the lab scale experiments, the conceptualisation and building of the ULTRACHOC precompetitive prototype was carried out in order to exploit the use of both Ultrasound technologies for improving the tempering process. The basic lay-out of the whole system consisted of a tempering machine to set up and circulate the chocolate, followed by the HPU device to treat it and finally by the UVPPD+USA measurement system to monitor the changes in the rheological properties of chocolate during tempering. In addition, a gear pump was added in order to increase the pressure of the chocolate, allowing the monitoring device to perform properly. The prototype was designed to enable the UVPPD+USA measurement system to be easily detached from the prototype in order to facilitate the future integration of the monitoring system in industrial production lines.
The final ULTRACHOC pre-competitive prototype was built with the support from the Consortium partners who actively supervised the construction work and provided inputs from their experience in industrial equipment and chocolate technologies. Both HPU and UVPPD+USA measurement devices were built and integrated according to design specifications. In addition, the prototype integrates a control and calibration software that enables full automated tuning of the tempering process in order to adjust the tempering process to meet the end-user pre-sets. Prior to the shipment and installation of the prototype at end-user sites, the correct and safe functioning of ULTRACHOC was verified through operational testing at IRIS. Such tests showed that the prototype was able to treat and circulate chocolate while keeping the temperatures within the specified limits, as well as monitor the temperature, pressure drop, velocity profile and attenuation. Thereafter, extensive tests were conducted to identify the optimal conditions for HPU treatment in the prototype setup using the parameters derived from laboratory experiments in previous WPs as starting point. An experimental plan was designed for assessing the effect of HPU treatment on the formation of beta V crystals, by comparing chocolate samples obtained by normal tempering with samples treated with HPU under different conditions. The output was the identification of the HPU conditions enabling a higher proportion of stable beta V crystals as compared to chocolate produced under conventional tempering conditions.
The system was then installed and tested at end-user sites according to a validation plan previously agreed. Chocolate samples generated during the industrial trials were shipped to SIK for evaluating the quality of the differently tempered chocolates by means of storage tests, fat bloom analysis, fat migration analysis, DSC analysis. Samples produced by the ULTRACHOC prototype were analysed and compared to samples produced by conventional tempering machines. Fat migration in the chocolate samples was studied by measuring the amount of oil that the samples take up during storage. The chocolate samples produced by the ULTRACHOC prototype with HPU showed better resistance to fat migration compared to samples with no HPU treatment. The development of fat bloom was analyzed by measuring the L*, a* and b* values of the surfaces of the chocolate samples and calculating the whiteness index (WI), which is a standard tool for quantifying fat bloom. During storage the HPU treated samples showed better or as good resistance to fat bloom as samples produced without HPU treatment, indicating that crystals transformed into the stable polymorphic states during storage. To summarize, high power ultrasound was found to affect the crystal structure of chocolate and to have potential to improve the quality of chocolate.
Regarding the UVPPD-USA system for monitoring on-line the temper status, the trials in industry showed that it was possible to penetrate 60 to 70% of the pipe diameter. Such a penetration depth allowed to obtain reliable and robust data for calculation of the velocity profile. Penetration depth which was an issue earlier in the laboratory trials at ETH was successfully overcome by optimizing power input as well as optimal placement of transducers and use of improved measuring cell material. The results indicated that this technology allows to detect changes in chocolate viscosity originating from tempering and cooling. Measuring TOF or Sound speed allows to obtain an additional signal that can be related to the degree of tempering.
Altogether, the research and validation trials demonstrated that the designed and built ULTRACHOC precompetitive prototype is a useful tool to both treat and monitor chocolate with ultrasound in a controlled manner. However, the relevance of certain operating parameters and/or equipment specifications could be identified, leading to further improvements that were suggested for future development work
Potential Impact:
The global chocolate manufacturing industry is one such industry that survived the recession without much impact on sales. In spite of falling disposables incomes in many countries along with the volatility in commodity prices, the global chocolate industry continues to grow. In fact, in the years to 2017, revenues from the global chocolate industry are expected to grow at a rate of over 2%. The European chocolate manufacturing market, comprising over 2000 companies and employing more than 200.000 people, has an annual turnover of approximately EUR43 billion and exports for a value of more than 3 billion euros
The global chocolate market is characterized by aggressive growth in developing regions and maturity and innovation in developed regions. With chocolate production shifting towards the growing region of South East Asia, countries such as India and China are emerging as markets with great potential for major chocolate manufacturers. Meanwhile in already mature markets the leading trend emerging is that of innovative products such as organic and natural chocolates and their established health benefits as well as the demand for new varieties and flavors. However, unfavourable factors such as an unstable supply of cocoa, spike in raw material prices, and labour becoming costlier are likely to inhibit growth in this market. Striking a balance between quality and pricing, however, remains a looming challenge for chocolate manufacturer.
The chocolate market remains highly polarised, with the top five manufacturers controlling around 50% of sales. With retailer own brands likely to take an increasing share overall, there will be even less room for branded products to develop. Consequently, manufacturers will also be called upon to work much harder simply to maintain their market share. Specific for the European market is the large proportion (over 90%) of small and medium sized enterprises which compete against multinationals by producing exclusive and niche oriented products. In this highly competitive environment, SMEs need innovation in order to achieve any further significant growth and development. By keeping the ULTRACHOC affordable and accessible to SME producers, as ULTRACHOC is rolled out across Europe, large communities of SMEs will be equipped to produce high quality chocolate and in a position to tap into the premium market that exists in Europe (and indeed worldwide) for chocolates of superior texture, taste and appearance. This will help to boost their profitability by selling their products at a premium price, which will help to buffer them from the effects of fluctuating raw material prices, and the threats of our precarious economic climate. The positive competitive impact that ULTRACHOC will have on European SME chocolate producers will contribute to product differentiation in the marketplace and increased productivity and growth of small companies
Developments such as ULTRACHOC offer high opportunity to create added value, novel offering and market differentiation, to contribute to increasing the competitiveness of chocolate producers, as well as European manufacturers and suppliers of equipment.
A key importance was given to the management of the intellectual properties and in agreement of the dissemination of non-confidential information throughout the project. The project developed know-how that will be exploitable by the SMEs. They plan to undertake future development efforts to bring ULTRACHOC from a pre-industrial prototype to a commercial system, and to perform practical evaluations of the technology and further demonstration work that will be bespoke to the chocolate manufacturing industry sector. Further funding to mitigate the cost of the additional development work will be applied for.
During the project life successful dissemination activities have been carried out to on the principles of the ULTRACHOC technology in preparation for the future exploitation of the technology. These include the development of a project website, number of technical articles and attendance to conferences and trade fair both in industry and in the public domain. Post-project, ULTRACHOC will continue to be disseminated, especially as a means for facilitating project-project exploitation of the results. The impact of the dissemination activities that have been carried out during the project have been measured in order to gauge their effectiveness based on quantitative and qualitative indicators.
Number of events at which the ULTRACHOC technology was presented – , 10
Number of industry visitors at trade shows and exhibitions - Over 100,000 professionals visited the events at which ULTRACHOC was exhibited.
Number of face to face meetings – 35
Number of policy makers reached - 5
Number of press releases and articles published in the press - 20
Number of hits on the project website - 1743
Followers on social media networks – 248
List of Websites:
Dr. Imma Llop
IRIS SL.
Avda Carl Friedrich Gauss 11
08860 Castelldefels
Spain
illop@iris.cat
+39035570111
ULTRACHOC was a two year applied research project, which commenced in January 2013 and finished in December 2014, and was funded under the “Research for SMEs” programme of the European Commission’s Seventh Framework Programme (FP7).
During the manufacture of chocolate a proper pre-crystallization or tempering process is demanded by the complex polymorphism of cocoa butter in order to obtain a high quality product. Tempering is critical for reducing processing failures and ensuring quality end product. Tempering is a highly complex process involving a series of careful temperature and mechanical energy input (by shear) controlled steps, whereby programmed temperature-shear-time processes are designed to obtain high quality chocolate products. Few solutions exist for controlling the tempering process of chocolate.
The overall goal of the project was to develop an on-line sensor system capable of measuring with precision and in real time the changes in the chocolate melt during tempering; and to control the crystallization of cocoa butter into the most desirable form (form V). The ULTRACHOC technology is based on the combination of the two ultrasound-based technologies that are readily integrated in a chocolate tempering machine i) High Power Ultrasound (HPU) for controlling the fat crystallization during tempering and ii) Ultrasound of low energy (Ultra Sound Doppler Velocimetry coupled with Pressure Drop measurement (UVPPD) for the development of an on-line sensor capable of measuring the temper level of chocolate, avoiding the need of the actual off line measurements. The ULTRACHOC prototype integrates a control and calibration software that enables automated tuning of the tempering process in order to adjust the tempering process to meet the end-user pre-sets.
of chocolate, avoiding the need of the actual off line measurements. The ULTRACHOC prototype integrates a control and calibration software that enables automated tuning of the tempering process in order to adjust the tempering process to meet the end-user pre-sets.
Project Context and Objectives:
Chocolate, a complex suspension, is a luxury food that during consumption evokes a range of stimuli that activate pleasure centres of the human brain. Textural and sensorial characteristics are fundamental to the overall quality and consumer acceptance of chocolate. Like many confectionery products, chocolate contains cocoa butter, which is obtained by pressing ground cocoa beans. It is a primary ingredient that allows chocolate to melt and flow easily in the mouth and this greatly influences the texture of the chocolate. One key element of the texture is that chocolate remains essentially a semi-solid at room temperature, but melts readily in the mouth at the normal body temperature of 37ºC. The physical and textural properties of this food depend on the microstructure formed during the crystallization of liquid fat and are affected by the processing and storage conditions. Fats, in general, feature a complex polymorphism, which is strongly influenced by its composition and heat, mass, and momentum transfer during crystallization.
Cocoa butter can crystalize into six polymorphic forms (I-VI) but only one, named beta crystal or Form V, is the most desirable form in chocolate, giving a glossy appearance, pleasant texture, good snap, contraction, good demoulding properties, stable shelf-life and resistance to bloom. Polymorphism of cocoa butter is an important material characteristic in chocolate manufacturing as it is directly linked to product quality and processing performance.
Due to the complex nature of polymorphism of cocoa butter, a process known as tempering is required during chocolate manufacture. Tempering is a complex thermal treatment of the fat phase of chocolate to form the proper type, amount and size of fat crystals. The key goal in conventional tempering processes is to achieve 1-2% solid fat content (SFC) in the tempering machine at a temperature where mostly Form V cocoa butter crystals can survive. To this end, in order to ensure the formation of crystals of the right polymorph form, good tempering involves a series of careful temperature and mechanical energy input (by shear) controlled steps, whereby programmed temperature-shear-time processes are designed to pre-crystallize chocolate in the correct manner.
The overall goal of the project was to develop a on-line sensor system capable of measuring with precision and in real time the solid fat content (SFC) of the chocolate and changes in the chocolate melt during tempering; and to control the crystallization of cocoa butter into the most desirable form (form V) by using ultrasound of low frequency. To this end the ULTRACHOC system combines in a unique system two methods for controlling and monitoring the tempering process, based on the one hand, on the use of high power ultrasound (HPU) to control the fat crystal size and polymorph distribution in the melt; and on the other hand, ultrasound of low energy for the development of an on-line sensor capable of measuring the SFC (Ultrasound Doppler-based Velocity Profile and Pressure Drop technique and Ultrasound Attenuation technique, UVPPD and USA).
The specific objectives can be summarized as follows:
• To use the results of a “bottom-up” research approach to gain understanding of the industrial needs and define the specifications of the ULTRACHOC system.
• To validate the use of high power ultrasounds (HPU) for improving the pre-crystalization of chocolate at laboratory level
• To validate at laboratory scale the potential of the UVPPD-USA technology for monitoring on- line the rheological properties of chocolate during tempering.
• To develop models for predicting resulting structure density in chocolate products and depending textural and stability properties.
• To gain an understanding of both technologies in lab-scale system systems in order to conceptualise and build the best industry applied prototype that integrates both technologies for monitoring and controlling the tempering process.
• To carry out calibrations and preliminary test to ensure the proper functioning of the system and its control unit.
• To install the prototype in industry to validate its performance in the field, comparing it to conventional tempering methods.
• To carry out quality analysis of chocolate samples resulting from industrial trials
• To make the necessary modifications and improvements to optimise the prototype and define future development work.
• To efficiently manage all knowledge-related matters arising from the project and to adequately protect project IPR embedded in the dissemination and use actions.
• To facilitate the uptake of the ULTRACHOC results by the participating SMEs, as well as by a wider audience, by carrying out demonstration activities.
• To draft a plan for the use and dissemination of the project results, as well as to plan activities for the future exploitation of the foreground.
The overriding goal of this project is to ensure that the pre-competitive ULTRACHOC prototype resulting from this project fulfills the threshold requirements to ensure its further development post-project into a fully industrial system that is taken to market, where its beneficial impact will be felt at European level.
Project Results:
The first target of the project focused on understanding the technological needs of European chocolate producers, as well as market needs and perceptions in terms of product quality, new technologies, etc. To this end, a questionnaire-based on-line survey directed to chocolate producers, and equipment providers was implemented as part of WP1. The gained in-sight was further broadened by desk research on market and socioeconomic information, literature reviews and patent searches on the technology at hand, and a number of on-site visits and in-depth consultations. With this information, both the industry and research partners worked closely to define the industrial needs of the proposed ULTRACHOC system.
A laboratory test rig allowing high power ultrasound (HPU) application at different temperatures, time and high ultrasound power levels, was set-up at SIK The potential of using HPU as a tool to improve the pre-crystallization process, i.e. the nucleation and crystal growth of polymorphic form beta-V fat crystals, in chocolate was thoroughly investigated. In order to extract as much knowledge possible on the effects of HPU on chocolate pre-crystallization process, experiments were conducted on both batch and continuous systems. Also, as the composition differs significantly between dark, white and milk chocolate, each chocolate sort was investigated individually with respect to optimal parameters during HPU. During batch trials each chocolate sort was evaluated with respect to penetration depth of acoustic energy, temperature distribution during HPU and fat crystal formation. Strength of the HPU treatment (generated power output), treatment time (continuous vs. pulses), static vs. dynamic conditions (shear vs. no shear), sample temperature and frequency were investigated parameters. During the continuous experiments, the parameters derived from the batch wise investigations were tested and further adapted in dark and white chocolate. The optimal conditions for HPU treatment for enhancing the formation of beta V crystals were identified in terms of frequency, amplitude, start temperature and duration of the treatment, providing the operating conditions for the scale up system.
In parallel, ETH started the experimental work with UVP-PD and USA with the aim to determine optimum device and measuring conditions to monitor the tempering of chocolate by a contactless, non-invasive on-line measuring. This objective was be achieved through a cascading approach starting with the design and build up of test stand, performing tests and measurements, relating online measurements to off-line analysis and finally deriving correlations between on-line measurement and off-line analysis allowing to characterize the quality of the pre-crystallization/tempering process. The experiments carried out clearly demonstrated that it is possible to measure viscosity of chocolate by means of UVP-PD. Furthermore it was demonstrated that the changes generated by temperature change or by crystallization of fat can be detected and measured by UVP-PD. Measurements of Time of Flight and attenuation also showed a clear influence of the temperature on the measured signals whereas different degrees of crystallization indicated a certain influence on TOF and attenuation. A major challenge of the given test set up was to achieve and maintain steady state conditions. Within the measuring time it was possible to achieve “steady state” but it was difficult to reproduce these conditions. Nevertheless, it was possible to derive Process-Structure-Properties functions that serve as a basis to establish predictive models. To accomplish this objective tests with one type of milk chocolate were performed applying different temperature conditions and different degree of crystallization in order to analyse the relationship between physical properties of the chocolate and the measured signals obtained by means of UVP-PD. Based on these measurements mathematical correlations were established that can be used to derive the degree of crystallization from the on line measured data.
In parallel with the lab scale experiments, the conceptualisation and building of the ULTRACHOC precompetitive prototype was carried out in order to exploit the use of both Ultrasound technologies for improving the tempering process. The basic lay-out of the whole system consisted of a tempering machine to set up and circulate the chocolate, followed by the HPU device to treat it and finally by the UVPPD+USA measurement system to monitor the changes in the rheological properties of chocolate during tempering. In addition, a gear pump was added in order to increase the pressure of the chocolate, allowing the monitoring device to perform properly. The prototype was designed to enable the UVPPD+USA measurement system to be easily detached from the prototype in order to facilitate the future integration of the monitoring system in industrial production lines.
The final ULTRACHOC pre-competitive prototype was built with the support from the Consortium partners who actively supervised the construction work and provided inputs from their experience in industrial equipment and chocolate technologies. Both HPU and UVPPD+USA measurement devices were built and integrated according to design specifications. In addition, the prototype integrates a control and calibration software that enables full automated tuning of the tempering process in order to adjust the tempering process to meet the end-user pre-sets. Prior to the shipment and installation of the prototype at end-user sites, the correct and safe functioning of ULTRACHOC was verified through operational testing at IRIS. Such tests showed that the prototype was able to treat and circulate chocolate while keeping the temperatures within the specified limits, as well as monitor the temperature, pressure drop, velocity profile and attenuation. Thereafter, extensive tests were conducted to identify the optimal conditions for HPU treatment in the prototype setup using the parameters derived from laboratory experiments in previous WPs as starting point. An experimental plan was designed for assessing the effect of HPU treatment on the formation of beta V crystals, by comparing chocolate samples obtained by normal tempering with samples treated with HPU under different conditions. The output was the identification of the HPU conditions enabling a higher proportion of stable beta V crystals as compared to chocolate produced under conventional tempering conditions.
The system was then installed and tested at end-user sites according to a validation plan previously agreed. Chocolate samples generated during the industrial trials were shipped to SIK for evaluating the quality of the differently tempered chocolates by means of storage tests, fat bloom analysis, fat migration analysis, DSC analysis. Samples produced by the ULTRACHOC prototype were analysed and compared to samples produced by conventional tempering machines. Fat migration in the chocolate samples was studied by measuring the amount of oil that the samples take up during storage. The chocolate samples produced by the ULTRACHOC prototype with HPU showed better resistance to fat migration compared to samples with no HPU treatment. The development of fat bloom was analyzed by measuring the L*, a* and b* values of the surfaces of the chocolate samples and calculating the whiteness index (WI), which is a standard tool for quantifying fat bloom. During storage the HPU treated samples showed better or as good resistance to fat bloom as samples produced without HPU treatment, indicating that crystals transformed into the stable polymorphic states during storage. To summarize, high power ultrasound was found to affect the crystal structure of chocolate and to have potential to improve the quality of chocolate.
Regarding the UVPPD-USA system for monitoring on-line the temper status, the trials in industry showed that it was possible to penetrate 60 to 70% of the pipe diameter. Such a penetration depth allowed to obtain reliable and robust data for calculation of the velocity profile. Penetration depth which was an issue earlier in the laboratory trials at ETH was successfully overcome by optimizing power input as well as optimal placement of transducers and use of improved measuring cell material. The results indicated that this technology allows to detect changes in chocolate viscosity originating from tempering and cooling. Measuring TOF or Sound speed allows to obtain an additional signal that can be related to the degree of tempering.
Altogether, the research and validation trials demonstrated that the designed and built ULTRACHOC precompetitive prototype is a useful tool to both treat and monitor chocolate with ultrasound in a controlled manner. However, the relevance of certain operating parameters and/or equipment specifications could be identified, leading to further improvements that were suggested for future development work
Potential Impact:
The global chocolate manufacturing industry is one such industry that survived the recession without much impact on sales. In spite of falling disposables incomes in many countries along with the volatility in commodity prices, the global chocolate industry continues to grow. In fact, in the years to 2017, revenues from the global chocolate industry are expected to grow at a rate of over 2%. The European chocolate manufacturing market, comprising over 2000 companies and employing more than 200.000 people, has an annual turnover of approximately EUR43 billion and exports for a value of more than 3 billion euros
The global chocolate market is characterized by aggressive growth in developing regions and maturity and innovation in developed regions. With chocolate production shifting towards the growing region of South East Asia, countries such as India and China are emerging as markets with great potential for major chocolate manufacturers. Meanwhile in already mature markets the leading trend emerging is that of innovative products such as organic and natural chocolates and their established health benefits as well as the demand for new varieties and flavors. However, unfavourable factors such as an unstable supply of cocoa, spike in raw material prices, and labour becoming costlier are likely to inhibit growth in this market. Striking a balance between quality and pricing, however, remains a looming challenge for chocolate manufacturer.
The chocolate market remains highly polarised, with the top five manufacturers controlling around 50% of sales. With retailer own brands likely to take an increasing share overall, there will be even less room for branded products to develop. Consequently, manufacturers will also be called upon to work much harder simply to maintain their market share. Specific for the European market is the large proportion (over 90%) of small and medium sized enterprises which compete against multinationals by producing exclusive and niche oriented products. In this highly competitive environment, SMEs need innovation in order to achieve any further significant growth and development. By keeping the ULTRACHOC affordable and accessible to SME producers, as ULTRACHOC is rolled out across Europe, large communities of SMEs will be equipped to produce high quality chocolate and in a position to tap into the premium market that exists in Europe (and indeed worldwide) for chocolates of superior texture, taste and appearance. This will help to boost their profitability by selling their products at a premium price, which will help to buffer them from the effects of fluctuating raw material prices, and the threats of our precarious economic climate. The positive competitive impact that ULTRACHOC will have on European SME chocolate producers will contribute to product differentiation in the marketplace and increased productivity and growth of small companies
Developments such as ULTRACHOC offer high opportunity to create added value, novel offering and market differentiation, to contribute to increasing the competitiveness of chocolate producers, as well as European manufacturers and suppliers of equipment.
A key importance was given to the management of the intellectual properties and in agreement of the dissemination of non-confidential information throughout the project. The project developed know-how that will be exploitable by the SMEs. They plan to undertake future development efforts to bring ULTRACHOC from a pre-industrial prototype to a commercial system, and to perform practical evaluations of the technology and further demonstration work that will be bespoke to the chocolate manufacturing industry sector. Further funding to mitigate the cost of the additional development work will be applied for.
During the project life successful dissemination activities have been carried out to on the principles of the ULTRACHOC technology in preparation for the future exploitation of the technology. These include the development of a project website, number of technical articles and attendance to conferences and trade fair both in industry and in the public domain. Post-project, ULTRACHOC will continue to be disseminated, especially as a means for facilitating project-project exploitation of the results. The impact of the dissemination activities that have been carried out during the project have been measured in order to gauge their effectiveness based on quantitative and qualitative indicators.
Number of events at which the ULTRACHOC technology was presented – , 10
Number of industry visitors at trade shows and exhibitions - Over 100,000 professionals visited the events at which ULTRACHOC was exhibited.
Number of face to face meetings – 35
Number of policy makers reached - 5
Number of press releases and articles published in the press - 20
Number of hits on the project website - 1743
Followers on social media networks – 248
List of Websites:
Dr. Imma Llop
IRIS SL.
Avda Carl Friedrich Gauss 11
08860 Castelldefels
Spain
illop@iris.cat
+39035570111