The Manufacture of Chocolate and other Cacao Preparations

by Paul Zipperer

To maintain connection of the steam and water pipes whilst the trough is reversed there are two flexible metal tubes. Both are screwed to the fixed pipes. For carrying away the vapour given off there is a tin plate cover to the trough, provided with a charging aperture and a channel inside to catch the moisture collecting on the cover and discharge it. When the machine is to be emptied, the cover is raised and a receiver adapted to the size and form of the machine is so placed that the charge can be diverted into it. The tilting of the machine is effected mechanically, and depends on the working of a lever. So as to prevent spurting of the liquid material when discharging, the stirring arms can be stopped for a time.

From this “Universal” Kneader and Mixer the special type “Vacuum Kneader”, system Werner-Pfleiderer, is distinguished, as its name implies, by a vacuum arrangement. As seen on illustrations 91 a and b, this comprises a pyramid-like cover made of cast iron, and shutting down air-tight, which is provided with indiarubber caulking, and binding screws, and is fitted up for steam heating. It moves on the frame of the machine and is counterpoised with weights, so as to facilitate its raising and lowering. On the front part of the lid there is a small aperture paned in with glass, and opposite on the interior in a specially protected compartment occurs an electric light arrangement, which admits of the continual observation of the material during the working up processes. In addition, small quantities of cacao mass can be introduced on removal of the glass pane without lifting up the lid; so that the advantages of the aperture are twofold. The upper part of the cover tapers off into a suction pipe, which itself terminates in a flanged support intended as a finish to the conduit from the airpump.

Fig. 91 b.

The kneading trough of the machine is made of cast iron, provided with a false bottom, and fitted up for heating with hot water or steam to a pressure of 7 atmospheres, or for cooling down with cold water. By way of rapid discharging, the trough is counterpoised with weights, and can easily be tilted over by means of a hand winch. Its interior, as also the kneading shovels, are clean scoured, and the bearings of the shovels stopped with easily adjustable stuffing boxes. These stuffing boxes (German Patent) are so fitted in that no greasing substances whatever can penetrate to the cacao mass, which is of the highest importance, as in the case of the ordinary stuffing boxes grease is sucked up into the kneading trough by the action of the air pumps and the material contained in this so rendered impure. The steam and water conduit to and fro is effected by means of supple metallic hose, which follow the movement of the trough as it is tilted.

The vacuum kneading machines have acquired great importance in the manufacture of milk chocolates, where it is chiefly a question of reducing mixtures of cacao, sugar, and condensed milk to a requisite thickness. Lately the value of the machine has been regarded as consisting in the main of the possibility of preparing cacao under vacuum which it affords.

It is easy to understand that the treatment of the cacao under vacuum demands a much lower temperature and takes place in about half the time requisite for open machines, where it must be carried out against the constant and contrary influence of the atmosphere, apart from the fact that the vacuum kneader preserves the aroma far better.

The alkali solution used in disintegration may be prepared in vats fitted with draw-off cocks, or, in small factories, in glass carboys such as are used for the conveyance of acids. Of the fixed alkalis, potash is preferable, since it is a natural constituent of terrestrial plants and therefore of the cacao bean, and so its employment introduces no foreign ingredient. Magnesium carbonate seems to find favour in many quarters, but we consider it less suitable as being insoluble in water, and therefore can only be incorporated with the cacao mass in a state of suspension. It is sufficient to have a potash solution some 90 or 95 % strong, answering to the requirements of modern medical treatises.[130] The salt is soluble in an equal quantity of water.

In preparing the solution, the best plan is to dissolve a known quantity in from 3 to 4 times as much water at the temperature of the room and then by diluting with water reduce this composition to the required strength. As for each 100 kilos of cacao still undefatted from 2 to at the most 3 kilos of potash and from 15 to 20 kilos of water are required, this 2 or 3 kilos of the salt should be dissolved in about 10 litres of water and the solution after diluted with the remainder of the water.

In using volatile alkalis, which are nevertheless falling into disuse more and apparently no longer maintain their reputation, ordinary ammonium carbonate which may be easily obtained in powder form at any chemist’s, or a solution of ammonia, such as spirits of sal-ammoniac, may be used. The former is easily soluble in about five parts of water. From ½ to 3 kilograms of ammonium carbonate are generally reckoned for every 100 kilos of undefatted cacao material, and this amount is dissolved in water, the whole of the salt being at once introduced into from 15 to 30 litres, as when smaller quantities are used there ensues a decomposition of the salt and one of the products of decomposition, the carbonate of ammonium, remains undissolved.