ALMOND CHOCOLATE
Pumping Almond Chocolate at a Stable Product Temperature
How to gently convey solid-laden chocolate mixtures
Industrial chocolate production places high demands on the conveying technology used. How can a sensitive chocolate mass containing solids be conveyed evenly without impairing its structure, shine or melting properties? And how can a constant product temperature be ensured while guaranteeing process stability and product quality?
These were the questions asked by a leading European chocolate manufacturer. They found the answer at NETZSCH Pumps & Systems, the global specialist in handling complex media. We will show you how to gently pump a chocolate-almond mixture at a constant temperature and in compliance with the strictest hygiene regulations.
Individual Consulting
Challenges when pumping almond chocolate
Chocolate mass is one of the most sensitive media in food processing. Even slight deviations in temperature or shear stress can alter the crystal structure of the fats it contains, thereby negatively affecting its melting behaviour, shine and mouthfeel. In this case, a solids content of up to 15 percent, combined with almond pieces up to six millimetres, significantly increases the demands on the conveying technology used for a long time. The pump must be able to convey media with a viscosity of 1,000 to 3,500 mPas evenly without damaging solids or causing blockages. At the same time, chocolate production is subject to strict requirements for food safety, cleanliness, and process stability. Dead spaces, pulsating conveyance or lubricant-contaminated drive concepts are unacceptable in this environment.
When conveying technology slows down the process
At a leading European chocolate manufacturer’s production plant, a chocolate-almond mixture had to be continuously conveyed from the melting tank to the downstream process line. The previously used conveying technology proved to be unsuitable. The chocolate mass, which contained solids, was conveyed unevenly, resulting in increased wear. In addition, temperature control was inadequate, leading to viscosity fluctuations and process instability. Maintenance costs were also high, cleaning processes were time-consuming, and the risk of product contamination was difficult to control.
Innovative pump for sensitive almond chocolate
NETZSCH recommended a TORNADO® T.Sano® rotary lobe pump for this application. The pump operates on the positive displacement principle with two counter-rotating lobes and is specifically designed for sensitive, solids-laden media in the food industry. This operating principle ensures the chocolate mass is transported gently from the melting tank to the downstream process line without any pressure peaks. A key design feature of the T.Sano® is the very small gap in the pumping chamber. This allows even almond pieces up to six millimetres in size to pass through the pump safely without causing blockages. Continuous and stable conveyance is guaranteed even with a solids content of up to 15 percent. Maintaining a constant temperature is also crucial to chocolate quality. For this reason, both the pump housing and the pump cover can be heated. As a result, the chocolate mass is conveyed at a uniform temperature of 45 °C, which supports the desired fat crystal structure and ensures a stable shine and optimal melting behaviour of the finished chocolate. The belt drive used replaces a classic gearbox, enabling completely lubricant-free operation. This eliminates potential product contamination while reducing maintenance requirements. In addition, the pump is designed according to the FSIP® principle and is CIP-compatible (Cleaning-In-Place). Cleaning and maintenance can be carried out directly during installation, minimising downtime and increasing plant availability.
All components of the T.Sano® rotary lobe pump coming into contact with the medium are made of stainless steel and polished to 0.8 µm. The elastomers used for seals and the pump cover seal are FDA-approved. A knife-edge mechanical seal ensures reliable and process-safe sealing even with sticky media. Since May 2019, the TORNADO® T.Sano® rotary lobe pump has been in continuous operation for up to 16 hours a day. Ever since, the almond chocolate mass has been conveyed continuously, with low pulsation and stable temperature. Compared with the previously used solution, process stability has improved because the flow rate is constant and precisely controllable. Despite high solids content, blockages no longer occur, while maintenance and cleaning costs have been significantly reduced thanks to the FSIP® design. At the same time, the product temperature is reliably maintained at 45 °C, which positively affects the chocolate’s gloss and melting behaviour.
Since the switchover, the operator has benefited from reliable, hygienically safe conveying and stable production, without unplanned downtime. If you would like to make your chocolate or food application more reliable and hygienic, the experts at NETZSCH will be happy to assist you in selecting and designing the right pump technology.
TORNADO® T.Sano® rotary lobe pump
- Medium: Almond chocolate
- Temperature: 45 °C
- Viscosity: 1.000 - 3.500 mPas
- Other: Up to 15 % solid content, almond pieces up to 6 mm
