FOOD ADDITIVES ASSIGNMENT

DESCRIBE THE ROLE OF EMULSIFIERS IN OTHER FOOD

PRODUCTS

DONE BY

PRADEEP CHANDRAN
URK17FP011
GIRIDHAR BALAJI URK17FP068
MULLAI RAJA RAJAN URK17FP078
TAMIL SELVAN URK17FP094
SANTHOSH URK17FP095
MOHAMMAD HAARISH URK17FP096
CHOCOLATE:
Chocolate is a food made from cacao beans. It is used in
many desserts like pudding, cakes, candy, ice cream, and Easter eggs.
It can be in a solid form like a candy bar or it can be in a liquid form
like hot chocolate. Commercial chocolate has sugar and
sometimes milk added.
Dark chocolate has less sugar, and a more bitter taste. It was originally
used to make drinking chocolate.
METHODS OF PREPARATION OF CHOCOLATE:
Step 1: Cleaning
The process of making chocolate starts with the cocoa beans being passed
through a machine that removes dried cocoa pulp, pieces of pod and other
extraneous material. The beans are carefully weighed and blended
according to specifications. Finally, the last vestiges of wood, jute fibres,
sand, and even the finest dust are extracted by powerful vacuum
equipment. The separated cocoa bean husks are passed on to the chemical
industry which extracts valuable compounds.
Step 2: Roasting
To bring out the characteristic chocolate aroma, the beans are roasted in
large rotary cylinders. Depending upon the variety of the beans and the
desired end result, the roasting lasts from 30 minutes to two hours at
temperatures of 250 degrees Fahrenheit and higher. As the beans turn over
and over, their moisture content drops, their colour changes to a rich
brown, and the characteristic aroma of chocolate becomes evident.
Although all steps are important, proper roasting is one of the keys to good
flavour.
Step 3: Shell Removal
The cocoa beans are cooled quickly and their thin shells, which have
become brittle by roasting, are removed. A giant winnowing machine that
passes the beans between serrated cones so they are cracked rather than
crushed. In the process, a series of mechanical sieves separate the broken
pieces into large and small grains while fans blow away the thin, light
shell from the meat or "nibs." Here's where the first secrets of the
chocolate manufacturer comes in. The nibs are blended, combining as
many as 8-10 varieties. It is control of these subtle mixtures that maintain
constant quality and brings out the flavour of each particular variety of
chocolate.
Step 4: Nibs are ground
The nibs, which contain about 53 % cocoa butter, pass through refining
mills and are ground between large grinding stones or heavy steel discs
creating a cocoa paste. The paste is subjected to hydraulic pressure, and
the cocoa butter flowing out is a pure and valuable fat with a marked
aroma; after filtering and purifying it looks very much like ordinary butter.
The cocoa butter has important functions. It not only forms part of every
recipe, but it also later gives the chocolate its fine structure, beautiful
lustre and delicate, attractive glaze. The heat generated by grinding causes
the cocoa butter or fat to melt and form a fine paste or liquid known as
chocolate "liquor". When the liquid is poured into moulds and allowed to
solidify, the resulting cakes are unsweetened or bitter chocolate.
Step 5: Cocoa is separated from Cocoa Butter
Up to this point, the manufacturing of cocoa and chocolate is identical.
The by-product of cocoa, cocoa butter, is the essential component of
chocolate… about 25% of the weight of most chocolate bars.
To make cocoa powder chocolate liquor is pumped into hydraulic presses
weighing up to 25 tons, and when the pressure is applied, 80% cocoa
butter is removed. The fat drains away through metallic screens as a
yellow liquid, and then is collected for use in chocolate manufacturing.
Cocoa butter, unique among vegetable fats, is a solid at normal room
temperature and melts at 89 to 93 degrees Fahrenheit just below body
temperature. With proper storage conditions, cocoa butter can be kept for
years without spoiling.
The "cake" which is left may eventually be made into cocoa powder by
being further crushed, milled and finely sifted. Three or five vertically
mounted steel rollers rotate in opposite directions. Under heavy pressure,
they pulverize the tiny particles of cocoa and sugar down to a size of
approx. 30 microns. Most manufacturers add non-fat milk, flavours, sugar
and other ingredients. The resulting product will contain between 10 and
22% cocoa butter. In the "Dutch" process, cocoa is treated with an alkali
and develops a slightly milder flavour, and has a darker appearance. The
alkali acts as a processing agent rather than as a flavour ingredient.
Step 6: Other ingredients are added to the Chocolate Liquor
Milk chocolate is made by adding milk, sugar, cocoa butter and other
ingredients to the bitter chocolate liquor. At this point, Chocolate is
prepared in according to individual recipes. The blending of the various
types of cocoa pastes and other ingredients determine the ultimate taste.
The ingredients go into a mixer with rotating, kneading arms until the
result is a homogeneous, paste-like mixture with a pleasant taste, but it still
feels gritty to the palate.

Step 7: Conching machines knead the Chocolate Paste

This process develops flavours and changes the texture during controlled
temperatures. It’s the last and most important refining process, which
allows the separate flavours of the individual ingredients to combine.
Conches are equipped with heavy rollers that plow back and forth through
the chocolate paste, anywhere from a few hours to several days.
Contemporary technologies can grind the chocolate particles extremely
fine, which can reduce conching times. Swiss and Belgian chocolates, are
conched as much as 96 hours. Some chocolates are not conched at all, or
for only 4 to 12 hours.
Under regulated speeds and temperatures, these rollers can produce
different degrees of agitation and aeration to create distinct chocolate
flavors. The process can eliminate any remaining bitterness by aerating the
chocolate and expelling volatile acids. Additional cocoa butter and lecithin
are added which help to achieve the characteristic velvet smoothness. And
as the ultimate homogeneity of the ingredients is developed, a soft film of
cocoa butter begins to form around each of the extremely small particles.
The chocolate no longer seems sandy, but dissolves meltingly on the
tongue. It has attained the outstanding purity which gives it its reputation.
The last stage of conching Swiss or Belgian chocolate is a magnificent
sigh huge paddles rolling slowly through great vats of chocolate, smooth
and creamy and thick.
 Step 8: Chocolate is Tempered by Heating, Cooling & Reheating
This thickens the chocolate and imparts the right flow properties for filling
the moulds. This complex operation is performed in the tempering plant
and is necessary to give the final chocolate product a delicate composition,
a uniform structure and a well-rounded flavor. The storage life is also
increased in this way.
The still warm conched chocolate is placed in a tempering machine so that
it can be slowly and steadily cooled. Cooling chocolate at a fixed rate
keeps the flavor from being compromised, and prevents separation when
the chocolate is poured into bar molds. Proper tempering also results in a
silky sheen and crisp "snap" when broken another sign of a superior
quality chocolate bar. The tempered chocolate is pored into molds of many
sizes, from individual sized bars to a ten pound blocks used by
confectionery manufacturers.
Step 9: Liquid Chocolate is Temporary Stored
A necessary step, conches are always filled with the largest amounts of
chocolate for efficiency, the molding machines can only accept small
amounts of chocolate paste at one time, in order to shape it into bars,
chocolates and other products. Chocolate is frequently shipped in a liquid
state to other food manufacturers, or it can be stored for short periods of
time. For longer periods, it is solidified, usually in the form of
hundredweight blocks. These blocks must be reheated before further
processing so that they liquefy again.

EMULSION:
An emulsion is a mixture of two liquids that do not combine
naturally, such as water and oil. We just think back to those salad dressing
science experiments from school. If you just lightly shake the liquid oil
mixture, you will see that the oil is floating at the top of the water. When
you rapidly mix the salad dressing, it seems to completely combine with
the liquids emulsifying to disperse one of them into the other in the form
of minuscule droplets. 

TYPES OF EMULSION INVOLVED:

There are two basic types of emulsions: oil-in-water (O/W) and
water-in-oil (W/O). In every emulsion there is a continuous phase that
suspends the droplets of the other element which is called the dispersed
phase. In an oil-in-water emulsion, the continuous phase is the water and
the dispersed phase is the oil while in a water-in-oil emulsion the oil is the
continuous phase.
Counterintuitively, the type of emulsion does not depend on the actual
amounts of oil and water present in an emulsion. For example, vinaigrettes
are oil-in-water emulsions even though there is more oil in a vinaigrette
than water (vinegar).
For most recipes, it doesn't matter what type of emulsion you've created, as
the end result is the same. The major exception is with dairy. Consider the
difference between cream and butter:
Cream and butter are literally the same thing. To make butter, you simply
mix cream until the emulsion reverses; that is, it transforms from a oil-in-
water emulsion into a water-in-oil emulsion. But despite this being the
only difference between cream and butter, the effect on taste and texture
are significant.
Most emulsions will not turn into butter even if you whip them for a long
time, but some emulsions can break down with too much stirring. For
example, a mayonnaise will not form correctly if it is over-beaten or the
oil is incorporated too quickly.
PROBLEMS ASSOCIATED WITH EMULSION:
The basis of chocolate is a delicate emulsion of cocoa solids and
cocoa butter. If it is improperly stored or tempered, the emulsion breaks
down causing either one or both types of "bloom" to occur - fat bloom and
sugar bloom, a colored film on the outside of the chocolate. Melting and/or
tempering bloomed chocolate eliminates the problem, although chocolate
affected with sugar bloom should not be melted and used for fine candy
making. 
Fat Bloom: The most obvious type of bloom, fat bloom, occurs when the
structure of the fat crystals changes during too-warm storage. It looks like
gray-white swirls or streaks on the chocolate when it is exposed to heat
during storage, usually warmer than 75 degrees F.
Sugar Bloom or Crystallization: occurs when the sugar crystals are
affected by moisture. This happens when the chocolate is stored in damp
conditions, either from humidity in the air or condensation from
refrigeration, causing sugar to dissolve and come to the surface, which
leaves it rough. It is visible as white streaks and dots and grainy texture.
When the water evaporates afterwards, the sugar on the surface
recrystallizes into rough, irregular crystals on the surface. You can prevent
sugar bloom by preventing temperature shocks. When chocolate comes out
of a cold room, it should be stored in a warm area long enough before
opening the package to keep direct condensation from forming. 
 

EMULSION SUGGESTED:
Lecithin is a phospholipid typically derived from soybeans or eggs.
In its liquid form, it is a yellow-brownish fatty substance with a fairly
thick viscosity.
Lecithin is very important to chocolate because it reduces viscosity,
replaces expensive ingredients such as cocoa butter, improves the flow
properties of chocolate, and can improve the shelf life for certain
products.
Viscosity reduction, or making a coating thinner, can certainly be done
by adding cocoa butter or other fats and oils, but it takes greater amounts
to accomplish this and is therefore more costly. 
HOW EMULSIFIER HELP RECTIFY THE PROBLEM?
LECITHIN:
1. As an emulsifier
Because soy lecithin is a fat, it is able to bond well with the fat
found in chocolate. This bond helps create an emulsification between the
chocolate and liquid when chocolatiers create ganaches. The soy lecithin
allows the moisture from cream, fruit puree or water to emulsify with
chocolate easily, creating a smooth ganache. The end result from this
process creates a shiny, homogeneous ganache that will melt in your
mouth.

2. To lower viscosity

Soy lecithin and cocoa butter provide the same function: they both
lower the viscosity of chocolate. Many chocolatiers prefer to add soy
lecithin over cocoa butter because less lecithin is needed than cocoa
butter to provide the same end result. This is important for chocolatiers if
they wish to create thin shells for molded chocolate truffles or thin
coatings on confections. The lower the viscosity is on chocolate, the
easier it is to temper chocolate. A lower viscosity chocolate will be more
fluid and easier to work with to develop Beta 5 crystals during the
tempering process. Depending on the needs of the chocolatier, they may
need to manipulate the fluidity (viscosity) of the chocolate to achieve the
best results in their creations. 

3. To improve crystallization

A thinner chocolate (low viscosity) will be easier to maneuver

over a slab of marble during the table top tempering process. For this
reason, many chocolatiers choose to use soy lecithin. It allows the
chocolate to become more fluid and easier to move across the
cold marble to create Beta 5 crystals. Beta 5 crystals are the most stable
form of cocoa butter, achieved only through tempering. These stable
crystals enable chocolate to have a beautiful shine, snap and melt at body
temperature.