Ball Mill Refining
Ball Mill Refining & Liquid Conching
Chocolate and compound coatings can be produced using distinctly different methods and equipment. In addition to conventional roll refining systems (with ‘dry’ conches) Kocotek also specializes in modern ball mill based systems (with ‘wet’ conches). We are also uniquely specialized in ‘hybrid’ systems that combine technologies from roller refining, ball mill refining, wet conching and dry conching). All these systems are made in house at the Royal Duyvis Wiener group in Holland. Depending on the type of chocolate (or compound coating) you wish to produce and each method and system has distinct advantages. We highly recommend exploring all methods of chocolate refining and conching we offer and encourage you to reach out to one of our experienced sales engineers to determine what method suits your project (and product!) best.
Pre-Mixing
The WiecoMix automatically and accurately weighs and mixes all ingredients needed to produce high quality chocolates and compound coatings.
WiecoMix: Continuous Batch Mixer
The WiecoMix is a ‘continuous batch’ ingredient weighing and mixing system consisting of two (2) vessels. First, all chocolate (or coating) ingredients are weighed and thoroughly mixed together in the top vessel. When the batch is complete it is rapidly transferred to the buffer vessel below and from there, the coarse ingredients are continuously pumped to the ball mill refiners (either vertical or horizontal).
Capacity
| Mixer Type | Capacities [lb / hr] |
|---|---|
| Wiecomix 350 | 1,600 - 2,800 |
| Wiecomix 500 | 2,800 - 4,400 |
Features
Accurately weighs all ingredients
Thorough, double action counter rotating mixing elements
Warm water jacketed for optimum product temperature
Fully automated
Small footprint
Benefits
Consistent, accurate and automatic weighing of all ingredients, even minor ones such as salt and vanilla
Accurate batch weighing combined with continuous flow to the ball mill refiners
In flight' weight correction for consistent production
Extremely intense mixing action ensuring a homogenous mass for refining
Ball Mill Refining
Our Royal Duyvis Wiener ball mills are used for refining of chocolate, compound coatings, spreads, fat based cremes and nut spreads.
Vertical & Horizontal Ball Mill Refiner
Our ball mills consist of grinding vessels filled with grinding media and a slow rotating specially designed shaft. The frequency controlled shaft causes small movements in the media that in-turn refine the coarse particles (crystal sugar is usually the coarsest ingredient). Typical end-fineness for a high quality chocolate or compound coating will be around 18 to 20 (metric!) microns. Deepening on the required capacity we can have one single ball mill or two (sometimes even three) in series. For smaller production runs we also offer stand-alone batch ball mills called a ‘WIECON’.
Refining Ball Mill Capacity
| Refining Ball Mill Type | Capacities [lb / hr] |
|---|---|
| Wiecon 50 (Batch) | 100 - 550 |
| W-105 (Batch) | 550 - 900 |
| W-70 | 1,000 - 6,600 |
| W-85 | 1,000 - 6,600 |
| W-90 | 3,900 - 8,500 |
Features
Excellent temperature control, particularly suited for very temperature sensitive products including sugar free chocolates
Frequency controlled, slow rotating shafts
Extremely durable mills, virtually maintenance free
Fully automatic, easy to operate
Modular system capacities expansion project available!
Benefits
Able to refine to 18 microns and less!
Product viscosity is stable and ready to use right away
Product temperature can be controlled up or down for optimum downstream processing
Ingenious quick 'change over' process - even when switching from a dark to a lite chocolate
NEW Generation 7 Ball Mill Refiner
Maintenance Reduction
Pillow Plate Technology
Gravitech Technology
By bundling experience, technology and customer input, Royal Duyvis Wiener has developed a brand new generation of machinery: it is sturdy and sustainable, solid and smart.
With our next generation Ball Mill the control over the refining process is even further improved, allowing you to efficiently produce a consistent high quality product. Our Ball Mill’s unique redesigned grinding vessel features a milling chamber with almost no dead-space. Less product in the ball mill during grinding ensures optimum grinding efficiency, better temperature control, and leads to a reduction of waste during product changes. This generation ball mill is the most effective by far.
Batch and Continuous Liquid Conching
Batch or continuous conching of liquid chocolates (and in some cases compound coatings too). The Batch Liquid Conche and Continuous Liquid Conches are designed to optimize the viscosity and perfect the flavor of chocolate and compound coatings
Batch Liquid Conche (BLC) and Continous Liquid Conche (CLC)
Batch Liquid Conche (BLC)
Continuous Liquid Conche (CLC)
Both the batch and continuous liquid conche combine a high sheer step with a thin-film reactor where the product is exposed to warm air, resulting in moisture reduction, removal of short chain free fatty acids and improvement of both viscosity and yield value
Liquid Conching Capacity
| Liquid Conche Type | Capacities [lb / hr] |
|---|---|
| BLC (Batch) | 1,100 - 2,800 |
| CLC1000 (Continuous) | 1,100 - 2,200 |
| CLC2000 (Continuous) | 2,200 - 4,400 |
Features
Easy to use system for liquid (melted) chocolates
Energy efficient
Small foot print
Economical solution
Benefits
Designed to optimize flavor of any chocolate
Chocolate viscosity will improve
Efficient removal of moisture and off-flavors from the chocolate
Research & Development
Process and product development for chocolates and compound coatings.
R&D Equipment and Facilities for Process and Product Development
Royal Duyvis Wiener is a unique supplier in that all chocolate production systems are also available on ‘pilot plant’ or ‘lab’ scale. From the small W1S ball mill, to liquid conches as well as single, double and triple shaft dry conches all pilot plant equipment is available for purchase. An alternate possibility is to spend a few days at the state of the Art, expertly staffed Royal Duyvis Wiener Technical Center in Koog aan de Zaan. All systems are available for testing and recipe development work there too!