Cocoa Powder and Butter Production
In 1828 CJ van Houten (a Dutch Chemist and Chocolate maker) patented a process for pressing cocoa butter out of roasted and ground cocoa nibs for the production of cocoa powder and cocoa butter. Over it’s 130 year existence Royal Duyvis Wiener expanded on the patent of Mr. van Houten and became the dominant global supplier for cocoa presses as well as powder milling and stabilization systems.
Cocoa liquor itself consists of two (2) components; cocoa butter and cocoa powder. In a cocoa press the ‘solids’ (what will be cocoa powder) and the ‘liquids’ (cocoa butter) are separated by pushing the liquor up against a screen in a closed chamber – the screen is designed to let the butter pass through but to keep the ‘solids’ inside the chamber. Depending on the needed capacity a press can have anywhere from 6 to 20 of these chambers, typically referred to as ‘pots’. Separating the butter from the solids requires an astronomical amount force (generated hydraulically), at the end of the cycle the pressure reaches a peak of about 1,000 bar force on the product (15,000 pounds on every square inch). Because there is so much force put on the product, the ‘solids’ come out as hard as a brick, which is referred to as ‘cake’ and is later processed into cocoa powder.
Duyvis Cocoa Butter Press
|Press Type||Capacities [kg / hr] – low-fat cake||Capacities [kg / hr] – high fat cake|
|4560/7||300 - 500||500 - 1,200|
|4560/18||500 - 1,450||1,000 - 2,850|
|4560/20||1,000 - 1,550||1,500 - 3,100|
|6080/18||1,250 - 3,000||3,000 - 5,000|
Precision design and manufacturing, high quality and patented technology
Use of only the highest quality durable materials, that are wear and distortion resistant
Low operational cost
Extremely durable, low maintenance reliable equipment
Residual fat content as low as 8% can be achieved
All parts standardized – Pots and counter-pots are interchangeable
A cocoa butter filter is used to remove any remaining ‘solids’ from the cocoa butter after being pressed. Cocoa butter is clear when liquid and turns opaque/white when crystallized. A second process step, known as ‘deodorization’, is a process generally used to strip all flavor components from the cocoa butter, which has a very mild flavor to begin with. Cocoa butter (like cocoa liquor) is supplied in bulk mostly to the chocolate/confectionery and cosmetics industry. Deliveries are usually in 25 kilo blocks that need to be melted or ‘liquid loads’ from tanker trucks.
Cocoa Butter Filter
With this new concept, the old-fashioned horizontal cocoa butter filter cloth press has been replaced by our fully automatic cocoa butter filtration system. The new cocoa butter filtration system makes manual cleaning redundant and virtually eliminates manual labor. The fully automatic cocoa butter filter consists of a pressure vessel with vertically suspended filter elements on the inside.
During the cocoa butter filtration process, unfiltered cocoa butter is pumped into the pressure vessel; while being pressed through the system the solid particles remain on the outside of the filter cloth. Compressed air is used to automatically clean the filter cloths. The deposit (slurry) falls to the bottom of the vessel and is subsequently pumped back to the liquor tank. After the automatic cleaning cycle the system is again ready for production.
|Cocoa Butter Filter Type||Capacities kg / hr|
|DBF750||250 - 750|
|DBF1250||750 - 1,250|
|DBF2300||1,250 - 2,300|
|DBF3300||2,300 - 3,300|
|DBF5000||3,300 - 5,000|
Clean and closed system, stainless steel
Continuous and fully automatic cocoa butter filter
Automatic removal of the 'solids' that is returned to the press room
Easy to operate
Virtually maintenance free
Integrated buffering capacity allows for a continuous flow of cocoa butter
Coca butter comes out absolutely crystal clear
Easy to keep clean
Milling & Stabilizing
ICM Cocoa Powder Mills and Stabilization
The ICM cocoa powder mill is a continuous system taking the kibble from the press and refines it in the milling chamber. By using a frequency controlled classifier the mill controls the fineness of the powder existing the mill. The mill is not only capable of deglomeration of the kibble is is also able to refine the solid particles if necessary. the mill is build from extremely durable precision engineered materials ensuring extreme up-time benefits. The mill is also easy to clean and requires very little maintenance – all up-to-date- safety features complying with ATEX or NFPA requirements are available. the stabilization system will ensure the formation of ‘beta 5’ crystals in the remaining fat in the cocoa powder ensuring a free flowing powder (no agglomerates!) with a bright color even after long term storage in big bags
|Cocoa Butter Processing Type||Capacities kg / hr|
|CPP 60||500 - 1,000|
|CPP 96||1,000 - 1,600|
|CPP 150||1,600 - 2,500|
|CPP 240||2,500 - 4,000|
|CPP 380||4,000 - 6,000|
Easy access for cleaning
Extremely durable low maintenance mill
Compact foot print & energy efficient
Built in frequency controlled cocoa powder classifier
Incorporates the latest safety features required by ATEX or NFPA regulations
Produces extremely fine cocoa powders
Stable cocoa powder, with 'beta 5' crystals, does not 'lump' after bagging
Short product retention time, easy product change over
Able to de-agglomerate kibble and also achieve size reduction of the solids
AMC Cocoa Blocking Line
The Duyvis tempering and filling systems are made specifically for the blocking-off of cocoa butter and cocoa liquor. The system can also handle most other fats and oils.
The tempering is based on the counter-flow principle. The cooler consists of one and up to four cooling reactors with internal rotating scrapers. A frequency controlled pump moves the product through the cooling tubes. The scrapers thoroughly mix the semi-crystallized mass away from the chilled cooling reactor surface.
The boxes are automatically filled to the exact weight. After approximately 5 to 20 minutes (for cocoa butter and cocoa liquor respectively), the product in the box is fully solidified and can be closed, transported and palletized.
During the short time it takes to transport the full box and replace it with a new empty box, the filling valve is closed and the product temporarily flows into a small buffer vessel. This buffer empties itself when the filling is started again, thus saving filling time and energy.
|Liquor Blocking Type||Capacity (kg / hr)|
|AMC3000||500 – 1,650|
|AMC5500||1,650 - 3,000|
|AMC7500||3,000 - 4,000|