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In the Candy Bar Line, the heating and melting process is one of the core links of production. The temperature control at this stage directly affects the quality, fluidity of the raw materials and the taste and appearance of the final product. The following is an analysis of the key points and importance of temperature control during heating and melting:
The impact of temperature control on product quality
Raw material characteristics and melting point
Different raw materials (such as sugar, cocoa butter, dairy products, etc.) have different melting points and thermal sensitivities. For example:
Sugar: It is easy to caramelize or crystallize at high temperatures.
Cocoa butter: Precise temperature control is required to maintain its fluidity while avoiding separation or oxidation.
Dairy products: High temperature may cause protein denaturation or produce odor.
If the temperature is too high, it may cause the raw materials to decompose, caramelize or change in flavor; if the temperature is too low, it may not be completely melted, resulting in uneven mixing.
Liquid raw material fluidity
The heated liquid raw materials need to have good fluidity so that the subsequent molding and infusion processes can proceed smoothly. Too low temperature will lead to too high viscosity, affecting the conveying efficiency; too high temperature may cause the raw materials to overflow or be overly diluted.
Key control points in the heating and melting process
Design of segmented heating curve
Low-temperature preheating stage
At the beginning of heating, gradually increasing the temperature at a lower temperature can prevent the raw materials from stress or agglomeration due to large temperature differences. For example, slowly heating sugar raw materials from room temperature to 50-60°C can help reduce the risk of crystallization.
Medium-temperature melting stage
When the raw materials reach a certain temperature, gradually increase the heating power to accelerate the melting process. The temperature range in this stage is usually 70-90°C, depending on the type of raw materials.
High-temperature stabilization stage
After the melting is completed, maintain a stable high temperature (such as 80-100°C) to ensure that the raw materials are completely liquefied and remain in a uniform state. However, long-term high temperature stays should be avoided to prevent raw materials from deteriorating.
Accurate temperature sensor and control system
Real-time monitoring
Use high-precision temperature sensors (such as thermocouples or infrared sensors) to monitor the temperature changes in the heating container in real time, and feedback adjustment is made through the PLC (programmable logic controller) system.
Zoned temperature control
For complex mixed raw materials, zoned temperature control technology can be used. For example, separate heating units are set up in different areas of the mixing tank to ensure that each raw material can melt at the optimal temperature.
Prevent local overheating
Stirring and heat distribution
During the heating process, continuous stirring can effectively prevent local overheating. The stirring speed and direction need to be optimized according to the characteristics of the raw materials and the shape of the container.
Indirect heating method
Using indirect heating methods such as water bath heating or steam heating can avoid direct contact with high-temperature surfaces and cause raw materials to burn.
Technical difficulties and solutions for temperature control
Avoid caramelization of sugars
Special treatment of sugar raw materials
Sugars are prone to Maillard reaction or caramelization at high temperatures, affecting product color and flavor. This can be solved by the following methods:
Add an appropriate amount of acidic substances (such as citric acid) to reduce the melting point of sugar.
Control the heating time to avoid sugars being in a high temperature state for a long time.
Stability of cocoa butter
Temperature sensitivity of cocoa butter
Cocoa butter begins to melt at 40-50°C, but exceeding 60°C may cause fat separation or oxidation. To this end:
Use constant temperature heating equipment to ensure that the temperature fluctuation does not exceed ±1°C.
After melting, quickly cool to a suitable processing temperature (such as 30-35°C) to maintain its stability.
Thermosensitivity of dairy products
Protection measures for dairy products
Dairy products are prone to protein denaturation or produce unpleasant flavors at high temperatures. Heat damage can be reduced by the following methods:
Add dairy products at low temperature to avoid long-term high temperature exposure.
Use vacuum heating technology to reduce boiling point and reduce loss of heat-sensitive ingredients.
In the future, with the development of intelligent and energy-saving and environmental protection technologies, temperature control will be more accurate and efficient, providing higher quality assurance for candy bar production.
