In this article we will discuss about:- 1. Introduction to Chocolate 2. Fermentation of Chocolate 3. Processing 4. Types 5. Usage 6. Preparing Chocolate Syrup 7. Adding the Cocoa/Chocolate 8. Freezing Characteristics.
Introduction to Chocolate:
Chocolate and cocoa rank second only to vanilla as flavouring for ice cream. They are obtained from cacao beans, the fruit of the perennial tree Theobroma cocoa, growing in such tropical regions as Mexico, Ghana, Brazil, Venezuela, Nigeria, Ecuador, the West Indies, the African Gold Coast, the East Indies, etc.
The origin of the cacao tree is in dispute. Like vanilla, it was introduced to the civilized world by Cortez in 1528. The cacao tree is a strictly tropical plant thriving only in hot, humid climates. As with vanilla beans, cacao beans must be subjected to a fermentation process before the characteristic flavour develops. Besides fermentation, a rather extensive processing of the bean is necessary before the flavour can be used in food products.
Fermentation of Chocolate:
The cacao trees of most strains will bear a full crop in the fifth year. The tree trunk and older branches bear pods, and there will be 25 to 40 beans per pod. The ripened pods, which are a rich golden red in colour, are cut from the tree, gathered in piles and left to ripen further for about 48 hours.
The pods are then slashed open, the beans removed and placed in bags for about 10 days to undergo fermentation, after which the characteristic flavour and rich brown colour develop. The beans are then washed, cleaned, dried (either artificially or under the sun) sufficiently to prevent mould growth, sorted and graded prior to shipment to manufacturers of chocolate and cocoa.
Processing of Chocolate:
At the factory the beans are first mechanically cleaned. Then they are roasted at a temperature of 121°C (250°F) or above for 30 minutes to 2 hours to eliminate the moisture and bring out the special chocolate flavour and aroma. The roasted beans are then quickly cooled by forced air, and run through a winnowing machine which crushes them into small pieces and separates the shells from the nibs (i.e., the seed part which is made into chocolate or cocoa).
Types of Chocolate:
There are several types of chocolate flavouring used in ice cream:
1. Chocolate Liquor:
This is a high-fat product. It is the trade name for the liquid chocolate which is produced by crushing the nibs between heavy stone grinders or mills which reduce them to a liquid (by heat generated by the friction of milling). It contains about 50 per cent fat and little flavouring material.
2. Cocoa Powder (Natural Process):
This is a low-fat product. It is made from chocolate liquor by subjecting the liquid to high pressure in hydraulic presses. This process removes a large amount of the cocoa-fat, usually about 38-40 per cent of the total, and leaves a hard dry cake which normally contains 10 to 24 per cent fat (average 22). It also contains nearly all the flavouring material from the cacao bean. This cocoa cake is then cooled, pulverized and sifted into cocoa powder.
3. Chocolate Blends:
These are combinations of liquor and powder. The fat content ranges from 36 to 40 per cent.
4. Dutch Process Cocoa Powder:
This is made as per the Natural process, except that the cacao beans are treated with certain alkalis at the time of roasting to break up the cell structure. This alkali treatment makes the cocoa more soluble and gives it the desired dark colour, which distinguishes the Dutch process from Natural cocoa.
It also helps to bring out the fully fine chocolate flavour when the cocoa is used in the finished product. Because the alkali counteracts the puckery acid taste which is found in Natural cocoa, Dutch process cocoa leaves no bitter taste when used as flavouring in ice cream.
Usage of Chocolate:
Chocolate products used in flavouring ice cream are:
1. Cocoa powder (20-25 per cent cocoa fat);
2. Chocolate liquor (50-53 per cent cocoa fat);
3. Chocolate blends (36-40 per cent cocoa fat);
4. Chocolate syrups.
The amount of cocoa or chocolate liquor/blends to be used in ice cream depends upon several factors, such as consumer preference, colour desired in ice cream, strength of flavour, etc. The usual recommendation varies from as much as 4 kg. of cocoa (or 6 kg. of chocolate liquor) to 100 kg. of mix. Extra sugar should be added to compensate for the bitterness of the cocoa or chocolate, the usual recommendation being to use the same weight of sugar as of cocoa or chocolate.
Preparing Chocolate Syrup:
The small manufacturer usually prefers to flavour chocolate ice cream by adding syrup at the freezer. Favourable results may be expected by using a formula of 20 kg. Cocoa, 20 kg. Sugar and enough water to make 38 kg. of finished syrup; 5 to 7 kg. of this syrup may be used to 19 kg. of mix. The syrup should be made in a chocolate kettle or double boiler.
Mix the sugar and cocoa/chocolate together and add enough water to make a heavy paste. Heat gradually and add water slowly as necessary. (The final syrup should contain enough water for it to pour when cooled.) The syrup should be heated to boiling point and cooled before use so as not to prolong the freezing operation.
Adding the Cocoa/Chocolate:
Whenever possible, an entire chocolate mix should be made by adding the cocoa (or chocolate) and extra sugar to the mix, along with the other dry ingredients, before pasteurization.
The temperature of pasteurization is sufficient to incorporate the flavour properly. A chocolate mix made in this way whips more rapidly than plain mix plus syrup at the freezer and gives a better-flavoured, more uniform product, free of dark specks.
The best chocolate ice cream is made when the chocolate mix is compounded and processed. A typical formula is as follows: fat—10 per cent, milk-solids-not-fat—10 per cent, sugar—18 per cent, cocoa —2.5 per cent, chocolate liquor—1.5 per cent, stabilizer—0.2 per cent and total solids —42.2 per cent.
Freezing Characteristics of Chocolate:
Chocolate ice cream is one of the most difficult to freeze because it whips very slowly. This is due to the fact that chocolate ice cream is very viscous. The viscosity may be reduced and whipping time improved by adding one kg. of citrate or phosphate to 1,000 kg. of mix.