COCOA AND BEAN TO BAR PROCESSING

By applying the traditional bean-roasting method, a microbiological improvement is achieved early in the process chain. By this the risk of cross contaminations during the winnowing stage is reduced. At the same time, the beans are being optimally prepared for the following de-hulling stage without the need for an extra heat treatment.

With a purpose-built winnower, utilizing multiple fraction sizes, the de-hulling stage is designed to achieve the best possible yield of the processed beans.

After being de-hulled, the cocoa kernels (nibs) are refined in compact, direct-drive grinders that possess excellent maintenance characteristics and are highly reliable in operation.

The resulting fine-ground cocoa liquor is stored in jacketed stirring tanks before it is either transferred to subsequent chocolate processing or tempered and filled into the desired packaging format.

Roasting

Our concept relies on a beans roasting technology. This is a traditional approach that bears certain differences compared to nibs roasting. During the roasting process the cocoa aroma is developing and at the same time the bacteriological characteristics of the product is being improved. Furthermore, the cocoa beans are being prepared for the de-hulling stage as the shells are turning fragile thanks to the heat treatment. Due to the aroma development, the roasting step is a critical process point, which is why our roaster offer an automated process control with possibilities of adjusting critical parameters such as temperature and time.

Specifications

Batch sizes: from 20 to 100 kg
Capacity: 30 to 200 kg/h

De-hulling

During the de-hulling step, the beans are being cracked and the shell fragments are being separated from the bean kernels (nibs). During this processing step the critical target is to achieve the highest possible nibs purity rate, without loosing nibs particles by mixing them with the shells. To achieve this the broken beans, the mixture of nibs and shells, is divided in fractions to enable a well-adapted separation process for each particle size fraction. The WNN Winnower can be adjusted in all relevant process parameters: feeding speed, breaker speed, breaker distance, suction chute height, suction valves and ventilator speed. By this, all bean types can be processed at a consistent high quality.

Specifications

Capacity: 50 to 150 kg/h

Refining

As the cocoa beans have been cracked and the shells have been removed, the nibs are object of a refining stage to form a so-called cocoa liquor. The refining is about achieving a high efficient grinding in relation to required output specifications and product throughput. Our refining stage can deliver a well-ground cocoa liquor and simultaneously being easy and efficient to operate and maintain.

Pre-Grinding

Our pre-grinding utilizes the stone grinding technology. This offer a well-balanced particle distribution with a low energy consumption and very easy handling.

Specifications

Capacity: up to 200 kg/h

Refining

For the final refining stage we offer ball mills. The range cover the typical small-scale batch process as well as a continuous refining layout. By studying key refining parameters, we can offer highly efficient refining solutions.

Specifications

Capacity: up to 200 kg/h

Storage, tempering and blocking

For product transfer, storage and tempering we can offer different customized solutions depending on customer requirement. For automated processes we offer transferring systems with jacketed product piping, heatable pumps, storage tanks and control systems.

Chocolate processing

For chocolate, spreadings and fillings production we offer batch ball mill units. Our mills have been developed with a focus on the unique needs that small-scale production require. With the help from innovative ideas we strive to continuously increase the quality of ball mill processing. By controllable refining time, recirculation rate and shaft speed, the refining process can be customized for each product and each requirement. Thanks to the controllable product recirculation flow the ball mill conching effect can be intensified.