- Informed changes and enhancements in the production process
- Controlled additions of fat and/or emulsifiers
- Greatly improve both process control and product quality
Viscosity plays a crucial role in chocolate manufacturing as it affects various aspects of the final product, including texture, flavour, and the overall quality.
Traditionally, chocolate manufacturers have measured viscosity offline, which hampers fine control of the production process. Critically, this approach doesn't provide real-time data on tempered chocolate, which is influenced by processing temperature and fat crystal formation.
There is a growing need for in-line sensors to improve the control of chocolate manufacturing for a number of reasons. To ensure the chocolate meets customer preferences, to reduce production errors, and to adhere to strict quality standards. Reducing the waste of valuable raw materials is also important, particularly with increasing commodity prices.
Confectionary giant Nestle installed a Hydramotion XL7 into their chocolate process and determined several key advantages:
a. Process Monitoring: Real-time monitoring of viscosity during production provides a better understanding of the manufacturing process.
b. Enhanced Process Control: In-line monitoring leads to more informed changes and enhancements in the production process, improving overall control.
c. Adjustment of Viscosity: Viscosity can be adjusted by controlled additions of fat and/or emulsifiers based on real-time data.
Nestle determined the viscosity of melted chocolate depends directly on two main factors - its fat content and the degree of tempering.
The XL7 viscosity sensor provides a single point viscosity value, and the noise-free trace responded well to process changes. This provided actionable insight into the process. The researchers also found the inline viscosity measurements to correlate well with the Casson plastic viscosity values measured off-line.
The researchers determined that in-line viscosity monitoring is a crucial factor in chocolate manufacturing, with the potential to greatly improve both process control and product quality.
Read the Nestle whitepaper available here: