US3904777A
Expired / Lapsed
US
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Process for continuously producing a roasted cocoa mass and for manufacturing a chocolate mass
Assignee: Intercontinental Great Brands LLC
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Filing: 1972-12-04
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Granted: 1975-09-09
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Expires: 1992-12-04
Abstract
Abstract A roasted cocoa mass or blend is produced in a continuous process by crushing raw cocoa beans after dehulling to form a liquid mass which is moved as a thin layer over and in contact with a smooth roasting surface heated to between 110*C and 150*C under atmospheric or reduced pressure. The thin layer liquid cocoa mass is moved over said roasting surface for not more than 12 minutes and preferably for a shorter time, whereupon it is rapidly cooled, preferably also in a thin layer form, to 80*C or less. The smooth surface is preferably the inner surface of a hollow cylinder, especially of a so called thin layer vaporizer. Prior and preferably also during the roasting the cocoa mass is subjected to a degassification in a flow of air or water vapor, preferably a counter-current flow. The first degassing takes place at a temperature no greater than 95*C and at a reduced pressure no greater than 0.5 kg/cm2 . A homogenizing step may precede the roasting step. The so produced blend is then mixed with the other components of a chocolate recipe, whereby said other components are preferably comminuted to fine form, and the mixture is then, if necessary, comminuted and homogenized in a concurrent or counter-current gas flow to form the finished chocolate mass.
Inventors
- 👤 Paul Martin Goerling
- 👤 Klaus Paul Ernst Zuercher
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 17:21
CPC Classifications
A; A23; A23G; A23G1/00; A23G1/02; A23G1/04; A23G1/042; A23N; A23N12/00; A23N12/08
Claims Analysis
Total Claims: 39
Claim 1
Independent Claim
181 words
IN A PROCESS FOR CONTINUOUSLY A ROASTED COCOA COMPOSITION, WHEREIN THE SHELLS OF RAW COCOA ARE REMOVED PRIOR TTO CRUSHING THE BEANS INTO A RELATIVELY LIQUIDS COCOA MASS, WHEREUPON THE LIQUID COCOA MASS IS ROASTED UNDER PRESSURE, THE UPPER LIMIT OF WHICH IS ATMOSPHERIC PRESSURE, BY MEANS OF INDIRECT HEAT APPLICATION FOR HEATING THE COCOA MASS TO A MAXIMUM OF 150*C, THE IMPROVEMENT CONSISTING OF ARRANGING A SMOOTH, CYLINDRICAL SURFACE SUBSTANTIALLY VERTICALLY, APPLYING THE LIQUID COCOA MASS AS A CONTINUOUS TIN LAYER TO SAID SMOOTH, CYLINDRICAL SURFACE AT THE UPPER END THEREOF, WHEREBY THE LIQUID COCOA MASS ADVANCES DOWNWARDLY IN THE FORM OF SAID CONTINUOUS THIN LAYER WHILE MAINTAINING SAID SMOOTH SURFACE AT A TEMPERATURE OF BETWEEN ABOUT 100*C AND 140*C FOR ROASTING SAID LIQUID THIN LAYER COCOA MASS, PASSING A GASEOUS OR VAPOROUS COUNTER-CURRENT FLOW OVER SAID ADVANCING THIN LAYER LIQUID COCOA MASS, WHEREBY ONE SIDE OF SAID THIN LAYER LIQUID COCOA MASS IS SUBJECTED TO SAID TEMPERATURE OF BETWEEN ABOUT 100*C TO 140*C WHILE THE OTHER SIDE OF SAID THIN LAYER COCOA MASS IS SIMULTANEOUSLY EXPOSED TO AND IN
Claim 2
Dependent Claim
181 words
IN A PROCESS FOR CONTINUOUSLY A ROASTED COCOA COMPOSITION, WHEREIN THE SHELLS OF RAW COCOA ARE REMOVED PRIOR TTO CRUSHING THE BEANS INTO A RELATIVELY LIQUIDS COCOA MASS, WHEREUPON THE LIQUID COCOA MASS IS ROASTED UNDER PRESSURE, THE UPPER LIMIT OF WHICH IS ATMOSPHERIC PRESSURE, BY MEANS OF INDIRECT HEAT APPLICATION FOR HEATING THE COCOA MASS TO A MAXIMUM OF 150*C, THE IMPROVEMENT CONSISTING OF ARRANGING A SMOOTH, CYLINDRICAL SURFACE SUBSTANTIALLY VERTICALLY, APPLYING THE LIQUID COCOA MASS AS A CONTINUOUS TIN LAYER TO SAID SMOOTH, CYLINDRICAL SURFACE AT THE UPPER END THEREOF, WHEREBY THE LIQUID COCOA MASS ADVANCES DOWNWARDLY IN THE FORM OF SAID CONTINUOUS THIN LAYER WHILE MAINTAINING SAID SMOOTH SURFACE AT A TEMPERATURE OF BETWEEN ABOUT 100*C AND 140*C FOR ROASTING SAID LIQUID THIN LAYER COCOA MASS, PASSING A GASEOUS OR VAPOROUS COUNTER-CURRENT FLOW OVER SAID ADVANCING THIN LAYER LIQUID COCOA MASS, WHEREBY ONE SIDE OF SAID THIN LAYER LIQUID COCOA MASS IS SUBJECTED TO SAID TEMPERATURE OF BETWEEN ABOUT 100*C TO 140*C WHILE THE OTHER SIDE OF SAID THIN LAYER COCOA MASS IS SIMULTANEOUSLY EXPOSED TO AND IN
Claim 3
Dependent Claim
16 words
The process according to claim 1, wherein said gaseous counter-current flow is a counter-current air stream.
Claim 4
Dependent Claim
18 words
The process according to claim 1, wherein said vaporous counter-current flow is a counter-current flow of water vapor.
Claim 5
Dependent Claim
30 words
The process according to claim 1, wherein the roasting time for the downwardly moving thin layer liquid cocoa mass ranges from 0.5 to 12, especially from 2 to 6 minutes.
Claim 6
Dependent Claim
27 words
The process according to claim 1, wherein said roasting is completed in a single downward passage of the thin layer liquid cocoa mass over said smooth surface.
Claim 7
Dependent Claim
28 words
The process according to claim 1, wherein said cooling is accomplished by moving said cocoa mass in contact with a cooling surface following immediately said smooth heated surface.
Claim 8
Dependent Claim
21 words
The process according to claim 6, wherein said liquid cocoa mass is moved in a thin layer over said cooling surface.
Claim 9
Dependent Claim
17 words
The process according to claim 1, further comprising drying the cocoa beans prior to said shell removal.
Claim 10
Dependent Claim
17 words
The process according to claim 1, further comprising fracturing the cocoa beans prior to said shell removal.
Claim 11
Dependent Claim
23 words
The process according to claim 1, further comprising maintaining the thickness of said thin layer in a range of 1 to 2 mm.
Claim 12
Dependent Claim
48 words
The process according to claim 1, wherein said raw cocoa beans are subjected to a preliminary degassification prior to said roasting, said preliminary degassification taking place at reduced pressure no greater than about 0.5 kg/cm2 and at a temperature no greater than 95*C, preferably between 50* to 90*C.
Claim 13
Dependent Claim
26 words
The process according to claim 11, wherein said preliminary degassification is performed by means of a gaseous or vaporous counter-current flow of air or water vapor.
Claim 14
Dependent Claim
40 words
The process according to claim 11, wherein said preliminary degassification of the raw cocoa beans takes place after the cocoa beans have been dehulled and comminuted and prior to said crushing of the beans into said relatively liquid cocoa mass.
Claim 15
Dependent Claim
29 words
The process according to claim 11, wherein said preliminary degassification of the raw cocoa beans takes place after said crushing of the beans into said relatively liquid cocoa mass.
Claim 16
Dependent Claim
30 words
The process according to claim 11, wherein said reduced pressure under which said preliminary degassification takes place ranges from about 5 to 100 torr, preferably between 10 to 60 torr.
Claim 17
Dependent Claim
26 words
The process according to claim 11, wherein said preliminary degassification takes place while the dehulled crushed beans are in a thin layer on a heated surface.
Claim 18
Dependent Claim
28 words
The process according to claim 11, wherein said preliminary degassification takes place while the relatively liquid cocoa mass is in a relatively thin layer on a heated surface.
Claim 19
Dependent Claim
16 words
The process according to claim 1, wherein said thin layer is formed as a whirling layer.
Claim 20
Dependent Claim
18 words
The process according to claim 1, wherein said roasting temperature is within the range of 115*C to 130*C.
Claim 21
Dependent Claim
21 words
The process according to claim 1, comprising homogenizing the cocoa mass by subjecting it to high shearing forces prior to roasting.
Claim 22
Dependent Claim
30 words
The process according to claim 20, wherein said homogenizing takes place under the influence of a gaseous medium flowing in the same direction as the advance of said cocoa mass.
Claim 23
Dependent Claim
17 words
The process according to claim 1, wherein said liquid cocoa mass is roasted on a conveyor dryer.
Claim 24
Dependent Claim
19 words
The process according to claim 1, wherein said liquid cocoa mass is roasted in a roller or drum dryer.
Claim 25
Dependent Claim
24 words
The process according to claim 1, wherein said cocoa mass is homogeNized prior to said roasting by subjecting the cocoa mass to supersonic frequencies.
Claim 26
Dependent Claim
24 words
The process according to claim 1, wherein said cocoa mass is homogenized prior to said roasting by forcing the cocoa mass through narrow slots.
Claim 27
Dependent Claim
143 words
A process for producing chocolate products, especially quality chocolate products, comprising producing a cocoa mass by comminuting dehulled raw cocoa beans, subjecting the comminuted cocoa mass to a first degassing prior to roasting, said first degassing taking place under reduced pressure no greater than 0.5 kg/cm2 and at a temperature no greater than about 95*C, homogenizing the degassed cocoa mass, roasting the degassed and homogenized cocoa mass in a thin layer at a narrowly maintained temperature within the range of 100*C to 140*C, said roasting taking place at a pressure no greater than atmospheric pressure, mixing the cocoa mass with chocolate ingredients to produce a chocolate mass, and subjecting the chocolate mass to a second degassing, at least one of said degassing steps taking place in a flowing atmosphere comprising a medium which is inert relative to the cocoa mass or chocolate mass.
Claim 28
Dependent Claim
143 words
A process for producing chocolate products, especially quality chocolate products, comprising producing a cocoa mass by comminuting dehulled raw cocoa beans, subjecting the comminuted cocoa mass to a first degassing prior to roasting, said first degassing taking place under reduced pressure no greater than 0.5 kg/cm2 and at a temperature no greater than about 95*C, homogenizing the degassed cocoa mass, roasting the degassed and homogenized cocoa mass in a thin layer at a narrowly maintained temperature within the range of 100*C to 140*C, said roasting taking place at a pressure no greater than atmospheric pressure, mixing the cocoa mass with chocolate ingredients to produce a chocolate mass, and subjecting the chocolate mass to a second degassing, at least one of said degassing steps taking place in a flowing atmosphere comprising a medium which is inert relative to the cocoa mass or chocolate mass.
Claim 29
Dependent Claim
16 words
The process according to claim 26, wherein a further degassing is performed simultaneously with the roasting.
Claim 30
Dependent Claim
29 words
The process according to claim 26, wherein said second degassing of the chocolate mass is performed simultaneously with a second homogenizing step in which the chocolate mass is homogenized.
Claim 31
Dependent Claim
22 words
The process according to claim 28, wherein said second homogenizing step is performed by subjecting the chocolate mass to high shearing forces.
Claim 32
Dependent Claim
21 words
The process according to claim 28, wherein said second homogenizing step is performed in the presence of a concurrent gas flow.
Claim 33
Dependent Claim
13 words
The process according to claim 30, wherein said concurrent gas flow is air.
Claim 34
Dependent Claim
13 words
The process according to claim 30, wherein said concurrent gas flow is nitrogen.
Claim 35
Dependent Claim
132 words
A process for producing a cocoa mass, especially for quality chocolate products, comprising the following steps: producing a cocoa mass or liquid by comminuting dehulled raw cocoa beans, subjecting the comminuted cocoa mass or liquid prior to roasting to a first degassing step, said first degassing step taking place under reduced pressure no greater than 0.5 kg/cm2 and at a temperature no greater than about 95*C, roasting the degassed cocoa mass or liquid while maintaining a narrow temperature range, said roasting taking place at a pressure no greater than atmospheric pressure, and subjecting the roasted and degassed cocoa mass or liquid to a second degassing step, at least one of said degassing steps taking place in a flowing atmosphere comprising a medium which is inert relative to the cocoa mass or liquid.
Claim 36
Dependent Claim
132 words
A process for producing a cocoa mass, especially for quality chocolate products, comprising the following steps: producing a cocoa mass or liquid by comminuting dehulled raw cocoa beans, subjecting the comminuted cocoa mass or liquid prior to roasting to a first degassing step, said first degassing step taking place under reduced pressure no greater than 0.5 kg/cm2 and at a temperature no greater than about 95*C, roasting the degassed cocoa mass or liquid while maintaining a narrow temperature range, said roasting taking place at a pressure no greater than atmospheric pressure, and subjecting the roasted and degassed cocoa mass or liquid to a second degassing step, at least one of said degassing steps taking place in a flowing atmosphere comprising a medium which is inert relative to the cocoa mass or liquid.
Claim 37
Dependent Claim
206 words
In a process for continuously producing a roasted cocoa composition, wherein the shells of raw cocoa beans are removed prior to comminuting the beans into a cocoa mass or liquid, subjecting the comminuted cocoa mass or liquid to a degassing step prior to roasting to remove volatile fermentation elements, said degassing step taking place under reduced pressure no greater than 0.5 kg/cm2 and at a temperature no greater than about 95*C, homogenizing the degassed cocoa mass or liquid prior to roasting by subjecting it to high shearing forces, spreading the homogenized cocoa mass or liquid to form a thin layer, roasting the thin layer of the degassed and homogenized cocoa mass or liquid while maintaining a narrow range of + or - 1.5*C of a roasting temperature which itself is within the range of 100*C to 140*C, further degassing said cocoa mass or liquid during the roasting, immediately following the roasting cooling the roasted cocoa mass to a temperature having an upper limit of 80*C, mixing the cooled cocoa mass or liquid with chocolate ingredients to form a chocolate mass, homogenizing the chocolate mass by subjecting the chOcolate mass to high shearing forces, and degassing said chocolate mass in the presence of an inert flowing medium.
Claim 38
Dependent Claim
206 words
In a process for continuously producing a roasted cocoa composition, wherein the shells of raw cocoa beans are removed prior to comminuting the beans into a cocoa mass or liquid, subjecting the comminuted cocoa mass or liquid to a degassing step prior to roasting to remove volatile fermentation elements, said degassing step taking place under reduced pressure no greater than 0.5 kg/cm2 and at a temperature no greater than about 95*C, homogenizing the degassed cocoa mass or liquid prior to roasting by subjecting it to high shearing forces, spreading the homogenized cocoa mass or liquid to form a thin layer, roasting the thin layer of the degassed and homogenized cocoa mass or liquid while maintaining a narrow range of + or - 1.5*C of a roasting temperature which itself is within the range of 100*C to 140*C, further degassing said cocoa mass or liquid during the roasting, immediately following the roasting cooling the roasted cocoa mass to a temperature having an upper limit of 80*C, mixing the cooled cocoa mass or liquid with chocolate ingredients to form a chocolate mass, homogenizing the chocolate mass by subjecting the chOcolate mass to high shearing forces, and degassing said chocolate mass in the presence of an inert flowing medium.
Claim 39
Dependent Claim
22 words
The process of claim 34, wherein said degassing of the chocolate mass takes place simultaneously with the homogenizing of the chocolate mass.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1978-09-08 | 1979-03-10 | 1979-09-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1982-09-08 | 1983-03-10 | 1983-09-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1986-09-08 | 1987-03-10 | 1987-09-09 | $7700.00 | Window Closed / Lapsed |