Feeding, Cleaning, Weighing
Reliable and efficient cleaning machines separate foreign material from the beans, after feeding the cocoa beans from feed hoppers, transportation systems and storage silos into the production line. The beans are fed through a continuous batch weighing system, which registers the amount of cocoa beans and the capacities of the complete process. Ensuring a perfect balance of line efficiency for liquor, powder, and butter is achieved.
Continuous Bean roasting
In the Lehmann Continuous Bean Roasters all flavours are retained within the nib. The shell protects the nib from over roasting. The beans pass through the roaster by gravity and are batched in layers. In each cycle, hot air passes through ensuring every bean receives the same treatment. The beans are then sterilised before winnowing.
Hot beans transferred from the roaster are fed directly into the sterilizer, which saves a great deal of energy and avoids contamination.
Continuous Nib Roasting
Before nib roasting, the shell has to be removed. The Lehmann pre-drier gently loosens the shell from the kernel. After the nibs are cleaned and winnowed, alkalising can take place. The new, specialised Lehmann alkalising system for nibs with high moisture content proves to be the most flexible system regarding flavour, colour and pH influence. After drying in the alkalising system, the roaster is fed with the pre-dried nibs. F.B. Lehmann continuous nib roaster guarantees a uniform treatment throughout the batches. This roasting method is popular due to low energy consumption, flexible flavour development, and excellent end-product colour.
Breaking & Winnowing
F.B. Lehmann high-end winnowing machines uses three stages of breakers to crack the cocoa beans. The controlled rotation speed of the breakers increases from one stage to the next, sorting broken beans between stages. Each bean receives sufficient energy necessary to break the shell. All sizes of nibs run through a vertical winnowing duct, where the turbulent airflow separates the light shells from the heavy nibs that fall onto the downstream collecting conveyer: Ready for milling and refining process to produce the highest quality cocoa liquor.
All industrial chocolate and cocoa processing machines produced by Duyvis Wiener are designed to make the production of chocolate processing plants easier and more efficient.
Cocoa Butter Pressing
The Duyvis Wiener butter press uses a combination of effective liquor preparation, a liquor filling pump, and a state-of-the-art hydraulic pump, to achieve high yields of separation. The pressing stage in a chocolate processing plant involves the butter being separated through filter screens, after which it is collected in a discharge vessel. At this stage in the production line, cakes are dropped onto conveyors. A disc is then used to push the cakes towards the breaker.
Cocoa Butter Filtration and Storage
The cocoa butter is filtered under low pressure. Any residue will sink to the bottom of the vessel where it is discharged via a slurry pump at regular intervals. The clean butter is stored in large tanks.
Butter and Liquor Tempering and Blocking
The industrial chocolate and cocoa processing machines, used in this part of the production line of dosing and packing of liquor or butter into large cardboard boxes operate on an automated basis.
Cake Pulverising and Powder Packaging
The cakes are grind into powder after passing through a metal detector. The cocoa continues through the production line of chocolate to a mill, surrounded by cooling air throughout the process. The chocolate processing plant pulverises the powder before it is cooled again. After this stage, the powder is then packaged.