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Asked on 03.07.2018.
Chocolate Filling

Hi

I am looking some advice  about Chocolate and Jam filled cookies ( co extruded Encrusted ) base on the following point .

1. What characteristics need for the chocolate & Jam ?

2.What kind of instrument need to produced the chocolate ? ( only for filling )

3. Please suggest me the reliable supplier for bake stable Jam ( For Filling purpose ) 

 
Answered on 03.07.2018.

Dear Rasika,


A lot of the questions you ask depend on the shelf life and texture (gel - hard/soft-, flowing, etc) you desire and the characteristics of your depositor.

Regarding jam: depending on the country you ask for; for some we know reliable suppliers as we either work or consult with them. 

Regarding the chocolate: are you talking about only fatbased, waterbased or emulsionbased filling?

Answered on 04.07.2018.

1. What characteristics need for the chocolate & Jam ? FIRST OF ALL THEY HAVE TO BE BAKESTABLE FILLINGS.. THEY CAN BE FAT BASED OR WATER BASED OR EMULSION BASED. I HAVE SO MANY EXPERIENCE RHEON JAPON TYPE COEXTRUDED MACHINE PRODUCTS. FOREXAMPLE THAT PRODUCT.

https://www.etietieti.com/eti-tutku-mosaic-biscuit-filled-with-cocoa-cream

2.What kind of instrument need to produced the chocolate ? ( only for filling ) IF U WANT TO MAKE FATBASED FILLING ..U NEED BALLMILL OR VALS SYSTEM .. IF U NEED EMULSION TYPE FILLING.. U NEED SPECIAL COOKING TANK SYSTEM..

3. Please suggest me the reliable supplier for bake stable Jam ( For Filling purpose ) 

http://gemak.com.tr/en/

https://www.tanisfoodtec.com

Answered on 04.07.2018.

Dear Rasika,

Fillings needs to be formulated with certain characteristic to be baked stable. That includes the type of fat, level of solids etc in the case of fat based ones.

In the case of fruit fillings, type of pectin, level of solids, type of sugar used. Needs to compliance with a test called HRS (Heat resistance stability). This test shows how much resist a filling after expose to a heat treatment.

Equipment to make the fat based ones can be a ball mill and also 5 roll refiners in combination with a ball mill depending on the quality of filling you want to make.

Please let me know if I can assist further.  Send me an e mail to :  roberto.pinedat@gmail.com



Answered on 11.07.2018.

Dear Rasika,


if you only make chocolate and you get your chocolate already Ready To Use, you could work with a double jacket tank and a tempering machine if you'd like. You can aerate that filling then as well, so that the crystallisation is less of an issue. We have made a few formulations, using chocolate or cocoa mass as a base, but best effect we hade when we used some moisture sources in the formulation to allow the stabilisers to work. Then the question at hand is: do you want to use chocolate, compound chocolate or just chocolate flavour (easier and cheaper).



Answered on 14.07.2018.

Dear Mr.Rasika,

Heat Chocolate filling it is difficult to make in house... You need a separate set up for this to supply you.  So it is better to buy from outside.   In this only dark chocolate (compound) heat stable and will get liquid consistency inside the cookie.  If you go for milk chocolate it is very difficult to get liquefied consistency in encrusted biscuits.  As our friend recommended it is best to use V60 HAAS machine than any other machines.  If you use other machines be prepared for inconsistent filling, weight variation across lines, and chocolate oozing out of the shell.

Regarding Bake stable jam filling Still I could not find right supplier to get proper encrusted cookie without drying problem inside the cookie.



Answered on 04.07.2018.

Dear Rasika

If the filling is only fat based.. so you need ballmill or vals system

I have so many experience with rheon machines or comas gea or rnk etc.. I can help u for production of coextruded fat based bake stable chocolate cream cookie. I established so many projects for my customers

Answered on 05.07.2018.

Its better to outsource both the products to avoid deviations in these two raw materials. in house you will face quality issues better to manufacture from outside with given baked stable qualities. 

Answered on 07.07.2018.

Dear Rasika, are you talking about real chocolate or compound chocolate? If it’s compound chocolate, then you only need a jacketed melting tank with a stirrer and a mono pump to feed it to the co extruded hopper. Best supplier for High speed Co extruder is Haas Meincke v60. 

Answered on 16.07.2018.

Dear All Members 

Thanks for all your valuable points ,actually we are not going to used compound chocolate as its high cost in africa, we ordered ball mill system to produce all our fat  base filling using cocoa mass with CBS or CBE fat  .Regarding about the Co extruder supplier from Italy. 


Answered on 18.07.2018.

Respected Mr. Rasika,

I came across a supplier of bake stable jam for filling purpose from Pakistan if you say I can send you his contact and he can send you samples of his jam for trials for encrusted and deposition on cookies both.

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