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Asked on 29.06.2021.

Choco Chips and Cookies

Dear All,

The addition of Chocolate flavoured chips is always a great way to get a chocolatey bite in the cookies. Most of us are aware that these are compound based.

SIZE & COUNT MATTERS: The larger the chip higher is the IMPRESSION of a real chocolatey feel (the eyesight connects instantly and frames the mental impression) but the issue is that of softening and spreading during baking. For a process where chips are added to the dough:

Q1: What is the most optimum count for the chips as "Count per 100 g"

Q2: Has real chocolate as well been tried for a quick meltdown in the mouth?

Q3: For a very premium cookie, if one does want to use REAL CHOCOLATE CHIPS, any thoughts?

Answered on 01.07.2021.

Hi Ajit

At very good chocolate question!

The reality is that "real" chocolate chips (where the fat is predominantly cocoa butter) ARE used widely across the industry - certainly in the UK and EU. Doing this provides the opportunity to make a claim on front pack that is appealing to consumers. Compound based chips can be significantly lower in cost but really only offer a slight improvement in hardness in the final eat and be more resistance to smearing/deformation in the dough mixing stage.. All chips will remelt during baking and reform after the baking stage.

Here are some answers to your Qs :

1) Optimum Count

Counts for chips are normally in "count per kilo" , and suppliers usually apply an accuracy tolerance of +/- 10%. Counts can range from 3,500/kg (relatively large) to 100,000/kg (very small - like dots). In my experience counts of 7,500/kg or 15,000/kg are commonly used. Some people use LESS of the 15,000/kg chips to give the impression that there are lots of chips present. Some also use a mixed size of chips to achieve the same impression.

Note that CHUNKSare normally specified by their 3D size eg 5mm x 5mm x 8mm. Chunks are commonly used in Premium cookies, but are more expensive and there are fewer supply options.

2) Real chocolate and quick meltdown in the mouth

You're correct to link the type of chip to rate of melt in the mouth - and this is largely linked to the type of fat, fat quantity and moisture content of the chips. Remember that when consumed, the chips are eaten with large pieces of cookie/biscuit in the mouth, so the difference between recipes is not as noticeable as it would be when a chocolate bar is consumed.

One thing to consider - older chips (that have had a chance to pick up moisture) will be more heat resistant during processing and in the mouth. Something to remember when NPD samples may be made with older chips and first production features more freshly made chips from a supplier ; the chips may perform very differently in the finished products.

3) Perception of "Premium"

This can be linked to the claim - "chocolate" v "chocolate flavoured", the amount and distribution of the chips, and the use of chunks rather than chips.

Just like in liquid chocolates and coatings, the recipe selected can affect :

- cost of the ingredient and profitability of the finished product

- ease of manufacturing and line performance

- product claim

- nutritional positioning

- consumer perception of quality and value

For these reasons the recipe design is critical.

I'm happy to help if you want help in the chocolate recipe optimisation.


Chocolate Consultant

Brett Beardsell Consulting

Answered on 02.08.2022.

A couple of added thoughts regarding this topic . 

Size and amount of chocolate chips should be driven what the consumer is looking for in the cookie , can you process it while getting good weight control and not breaking too many wires and lastly can you afford the recipe . 

Regarding size,  there are many ways to go about this , 4200 count per pound is the standard size but I have seen products with combination of large and small drops as well as rods which also provide the consumer a unique visual and tasty chocolate experience.

Companies may choose to use compound chips or chocolate chips pending price of chips at the time or the consumer proposition on pack and in advertising . There are some very nice compound chocolate chips out there with minimal consumer trade off pending market you are targeting 

Smearing or marbling of the chips during mixing can be controlled by cooler dough temperature, cooling of chips prior to mixing , controlling the amount of dough in hopper to minimize churn as well as the use of dextrose added to the chip formulation. Dextrose at low levels does an excellent job controlling  both pre and post bake smearing and marbling of the chocolate. 

Answered on 01.07.2021.

Dear Mr Tawde

In biscuit making doing cookie with real chocolate is very difficult as the dough temperature in dough making in any short dough format will be minimum 25-28*C depending upon the environment conditions.  (even in case air conditioned mixing section)

Melting point of the chocolate is less than this then it will start mixing with dough and change the dough colour.  or even in during manufacturing either by extruding machine or wire cut machine or moulder in each machines there will be abrasion and friction due to machine part movement due to which dough temperature alters slightly and there are chances the chocolate chips get melted or broken due to its nature being pure.

Moreover another factor comes oven.  With all complication even we do with pure chocolate chips the intent of the final product will have different look as what you perceive and what you get and that will be challenge.  

It is easy to make in home and do individual consumption.

These are all perceptions only.  Still I think no one tried cookies with pure chocolate chips manufacturing.

Answered on 01.07.2021.

Dear Brett,

Many thanks for that detailed response. Appreciate your efforts. I will stay connected. Regards.

Dear Srini,
Many thanks for your response. Always a pleasure to connect. Regards.

Answered on 02.09.2021.

Dear Ajit

Additionally, I would say that it is possible to make a premium chocolate chip cookie with 22 to 24%  of chips. You could mix two counts of chips (i.e. 2000/4000), or even use a small fraction of this amount as compound chips, if cost is a problem. Also, mixing slightly bitter and milk chocolate chips is not uncommon. The product will not lose its premium appeal.

Best Regards,


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