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Post by tony on Jun 29, 2010 11:43:12 GMT -5
Hi All, Coming from an engineering background I'm inclined to think of things like - 'losses', more specifically, Production losses. I'm shocked to read of 25% weight loss due to shells, more as a result of moisture during roasting, losses during grinding, not to mention what is left in the conching phase. Are there any estimates of losses throughout the chocolate making process? Food for thought.... Its about time the gods did less eating and more thinking.... oh and is there a specific heat capacity for cacao beans?
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Post by Brad on Jun 29, 2010 11:52:59 GMT -5
From my experience loss occurs during roasting and through removal of the shell, but haven't experienced 25%.
Curious to know where you get loss during grinding and conching? The only loss we would potentially experience at that stage is through the expiration of a bit more moisture in the other ingredients, but here in Alberta, it's VERY dry, so the loss is negligible.
I could see losing considerable percentage by weight if the geographic area in which you are making chocolate is very humid, and the beans, sugar, and other ingredients have absorbed quite a bit of moisture. Maybe that's what you're referring to???
Brad.
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Post by tony on Jun 29, 2010 12:01:14 GMT -5
Brad, Thanks for that... Are you able to put losses to each stage of the production process. Or am I being a litle over the top?
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Post by Sebastian on Jun 29, 2010 18:52:24 GMT -5
You can expect roughly 15-20% shell loss if you've got thorough winnowing (some nib will stick to shell). You may create another 1-2% fines depending how your nib grinder works. You may expect a few % moisture loss during roasting as well as conching, and a very small volitile loss in both. All this is assuming clean beans - if you've got trash, rocks, clumps, diseased beans, infested beans, etc - you'll likely be removing those as well...
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Post by itsallaroundyou on Jun 29, 2010 19:49:08 GMT -5
Following through the production steps, you also have loss when you remove the finished chocolate from your machines, as well as what sticks to utensils, along with drips and drops during molding. In a very large batch, these are potentially negligible, but on santha-sized batches they are more significant. I read in post somewhere that generally speaking 1 kg unprocessed beans will make 1 kg 70% dark chocolate, which, if you included what Sebastian mentioned--tainted beans and foreign material--you get pretty close to that estimate. I think my biggest loss as a home chocolate maker come from dipping my finger in every hour...but i guess that's my fault -mike
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Post by tony on Jun 30, 2010 1:10:51 GMT -5
Well, i feel somewhat vindicated. The replies so far seem to suggest that we dont pay nearly enough attention to 'losses' as we should. In fact for any chocolate maker not to, might suggest that either they are making to much $ or they arent doing as as well as they think. Myself, I prefer to know that if Im paying $3200/MT and Im loosing 20% of that to shells that Im infact paying $3200 + 20% + Moisture losses (+_ 8%) + other losses and that in reality its quite a costly affair..... just my musings.
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Post by cocoa on Jul 1, 2010 3:34:46 GMT -5
wow!..If you join forums and read its topic, no wonder you will learn lots of information that can help you everyday..wew!
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Post by Brad on Jul 1, 2010 13:52:58 GMT -5
Tony;
You're missing a few things:
1. You paid $3200 / ton for your beans. You also paid to ship them. Therefore you also paid to ship the shell. You need to calculate 20% of your shipping and handling costs.
2. Good business dictates that with a little ingenuity, and marketing prowess, you should be able to turn your "losses" into a profit center. Once the beans have been seperated from the shell, the beans are no longer called beans. They're called nibs. Coincidentally, the shell is no longer called shell. It's called "Pot Pourri" - which when packaged nicely in 200g cello bags, and then steeped on the stove briefly, turns your customer's house into a rich, brownie smelling paradise, and an at-home reminder of why they shop with you.
Let's calculate this: 200 kg of "lost" shell X 10 packages per kg X $5 per package - ($1 per package for packaging, labelling and handling) X 200 kg of shell X 10 packages per kg ) = FREE cocoa beans, PLUS your next ton of cocoa beans free too! Oh.... Wait.... You get shell with THOSE too. Holy Moly! Now your shells pay for your beans.
My invoice for this valuable piece of advice is in the mail. I'm sure with the copious amount of profit you're going to make from it, you should have no problem with payment! LOL
Having said that, if you don't want your roasted shells, ship it to me. I'll take it free and pay for the shipping and handling!
Brad.
Footnote: Sebastian, I don't want all the shell you create. I'm good at sales and marketing but not THAT good! LOL ;D
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Post by doclogic77 on Jul 2, 2010 21:37:50 GMT -5
So you steep the shells in water and the steam makes the house smell like brownies? Sorry don't know how this pop pourri thing works.
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Post by Brad on Jul 3, 2010 17:07:53 GMT -5
Yup. Put the shells in water, bring to a boil, and shut off the heat.
That's it.
Presto. Brownie Smell.
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