Traditional Roller Refining
Chocolate Manufacturing System
State of the Art Chocolate Manufacturing Systems
For chocolate and chocolate coating production, Kocotek specializes in traditional five-roll refining combined with dry conching, as well as, the modern ball mill production technology, combined with either a continuous ‘wet’ conche or a batch ‘dry’ conche. Each system offers its own unique advantages and is available in capacities ranging from small scale artisan (or ‘pilot plant’) all the way to large industrial production systems.
Chocolate Paste Mixing
The paste mixer is the first step in the conventional ‘roller refined’ chocolate production process. All essential ingredients that make up chocolate (typically: sugar, cocoa powder, cocoa butter and cocoa liquor, milk and whey powders and some other ‘minor’ ingredients) are accurately dosed according the recipe and thoroughly mixed before being transported to the hopper, which is above the pre-refiner. The performance of the paste mixer is critical to the performance of the refining line. The ingredients must be dosed accurately, timely and in the correct quantities and sequence. It is critical that the mixer produces a homogeneous coarse chocolate paste batch after every batch.
Dry Batch Paste Mixing System
Dry Batch Mixer
Dry Batch Mixer - Interior
The Thouet paste mixer is placed on load cells and for optimum and efficient mixing has two (2) specially designed horizontal mixing shafts each fitted with very strong helical geared motors. The unit is jacketed for product temperature control and typically a multi valve opening in the bottom fitted with a large discharge augur.
The well-proven design of these Dry Batch Mixers ensures enough mixing time after ingredient dosing for a homogenous dough or paste and can handle up to 3 batcher per hour.
Capacity
| Horizontal Mixer Type | lb / hr |
|---|---|
| DM(S/K)-500 | 1,000 - 3,000 |
| DM(S/K)-1000 | 3,000 - 6,000 |
| DM(S/K)-1500 | 6,000 - 9,000 |
| DM(S/K)-2000 | 9,000 - 13,000 |
| DM(S/K)-3000 | 13,000 - 20,000 |
Features
Double trough tank with two mixing shafts for optimum mixing efficiency
Load cells and/or loss in weight feeding
Specially designed elements for mixing and kneading of chocolate
Benefits
Self aligning roller bearings
Can handle three (3) batches an hour
Optimum and uniform mixing of all ingredients
Double shaft mixer for chocolate ingredients,
Different models for crystal (DMS) and powdered (DMK) sugar
Steel Belt Conveying
Typically installed on floor mounted columns, conveyors are used to transport chocolat flakes throught the chocolate manufacturing system. Conveyors may also be installed using cieling suspension with special fixing devices.
Steel Belt Conveyors
The steel belt transport system is specially designed to efficiently transport chocolate flake from the pre-refiner to the five roll refiner and from the five roll refiner to the conches. Motor power varies by conveyor length.
Capacity
| Belt Type | lb / hr |
|---|---|
| TRB-4 (belt with 400mm) | 1,000 - 11,000 |
| TRB-5 (belt with 500mm) | 11,000 - 23,000 |
Features
Sanitary design with stainless steel frame and either stainless or makrolon covers
Larger than normal drums on the drive and turn-around stations allowing for much thicker than typical steel belt
Specially designed Scrapers
Available with 'self cleaning' brush system
Typical max length is 130 feet but longer belts can be supplied too!
Benefits
Gentle inclines to prevent 'roll back' of the product
Belt thickness results in significantly lower chance of failure
Extra wide belts allowing for reduced speeds also at higher capacities (less dust)
Sanitary design stainless steel or makrolon covers for food safety
To minimize friction the belt is roller supported through-out
Pre-Refining
2-roll refiners are used as pre-refiners in chocolate manufacturing systems. Chocolate paste is pre-refined from a coarse crystal sugar to a particle size of 100 – 200 microns.
Pre-Refiner: 2 Roll Refiner
From the paste mixer the coarse unrefined chocolate paste is transported to the buffer above the pre-refiner. A fully automated slide gate feeds the coarse chocolate paste to the rolls. The rolls can be driven by one (1) single frequency controlled drive, or by two (2) frequency controlled drives to have ore flexibility in setting up the speed differential.
Capacity
| Pre-Refiner Type | Roller Width | lb / hr |
|---|---|---|
| WZ9 | 900 mm | 2,200 - 8,800 |
| WZ13 | 1,300 mm | 8,800 - 13,000 |
| WZ18 | 1,800 mm | 13,000 - 24,000 |
Features
Latest sanitary, hygienic design, stainless steel machine making it a 'easy clean'
Easy dismantling of the rolls when they need to be re-cut
Double use scraper knives
Rolls have individual temperature control
Specially designed hydraulic pressure system with gap controls
Benefits
Produces homogenous chocolate flake, ideal for the 5 roll refining step
Pre-wetting' of the product for optimum refining results
Very durable rolls for consistent product quality
Easy clean discharge augur with additional mixing action
5 Roll Refiner
The 5-roll fine refiner recieves the chocolate flake from the pre-refiner by the conveyor belt. The chocolate flake is then refined down to 20 metric micron, typically, though finer particle size is also possible.
Fine-Refiner: 5 Roll Refiner
5 Roll Refiner
5 Roll Refiner - Interior
Well over a century of experience!
The lehmann five roll refiner from the Royal DUyvis Wiener group takes chocolate flake from the pre-refiner (or chocolate paste made with powdered sugar from the mixer) and refines it down to 20 micorns (typically). Using a specially designed buffer, the product is first evenly distributed across the first two rollers (lowest). Because of the pressure and the speed differential between the rolls, the product is picked up and refined more and more between each susequent set of rolls. The five roll refiner has four (4) refining steps, each roll has a different speeds. Pressures are controlled as well.
Capacity
| Dry-Conche Type | Triple-Shaft Type | Batch Capacity (lb) |
|---|---|---|
| RC1000 | 2,000 | |
| RC2000 | 4,400 | |
| RC3000 | DRC3-3000 | 6,600 |
| RC4000 | DRC3-4000 | 8,800 |
| RC6000 | DRC3-6000 | 13,000 |
| RC9000 | DRC3-9000 | 20,000 |
Features
Specially designed, easy to exchange rolls
Rolls 1 and 2 are dynamically controlled for active refining step
Multi drive, frequency controlled technology available
Individual temperature control on each roll
Sanitary design, easy clean system
Benefits
Very tight particle size distribution for optimum chocolate viscosity potential
Able to refine to 12 (metric) microns
Automatic dry run protection
Available with dual particle size management system on roll #5
Available with water cooled drives to minimize generation of dust
Dry Conching
The Thouet dry conche from the Royal Duyvis Wiener group is used to lower the moisture content of the chocolate and with that improve the rheological properties. Also, undesierable flavor profiles can be removed and other flavor profiles can be created or accentuated.
Dry-Conche Type RC
Capacity
| Dry-Conche Type | Triple-Shaft Type | Batch Capacity (lb) |
|---|---|---|
| RC1000 | 2,000 | |
| RC2000 | 4,400 | |
| RC3000 | DRC3-3000 | 6,600 |
| RC4000 | DRC3-4000 | 8,800 |
| RC6000 | DRC3-6000 | 13,000 |
| RC9000 | DRC3-9000 | 20,000 |
Features
Optimum temperature control using full jacket design, efficient insulation and efficient heat exchangers
Very powerful drives for optimum sheer forces at the end of the conching cycle
Stand alone, closed loop heat exchangers
Fully automatic venting/louvre control
Optional load cells
Benefits
As much as 1% butter savings compared to conventional conches
Optimum viscosity development
Optimum flavor development
Fully automatic addition of cocoa butter and lecithin
Certain models available in stainless steel - excellent for the production of white chocolates!
Research & Development
Equipment on a pilot plant scale for is used for testing and experimenting with the process and product development of chocolates and compound coatings.
Research & Development Equipment
Research & Development Center
2x5 Roll Refiner (Pilot Plant sized)
Paste Mixer (Pilot Plant sized)
Complete process line for the small scale production of chocolates and compound coatings. Ideal for product and process development work. Equipment line up includes paste mixing, pre-refiner, five roll refiner, single, double and triple shaft ‘dry’ conches as well as ball mills and ‘wet’ conches.