Patent Description:
<CIT> discloses a method of manufacturing a chocolate product comprising mixing two mixtures. The first mixture comprises inulin, whole milk powder, cocoa butter and lecithin, wherein the first mixture is refined and conched. In parallel, the second mixture comprises cocoa liquor or mass, cocoa butter, flavourings and fructose, wherein the second mixture is refined and conched. The two mixtures are then blended. The cocoa liquor is added at the beginning of the conching step of the second mixture. There is no mention of adding at least some of the cocoa liquor during or after the liquefying phase of the conching step or after the conching step.

<CIT> discloses a method of manufacturing a chocolate product comprising mixing two ingredient mixtures. The first mixture comprises a dry paste of size reduced cocoa butter substitute and sugar and the second mixture comprises cocoa powder, emulsifier, non-fat milk solids, cocoa liquor, lactose and milk which is mixed and refined. The two mixtures are then combined and conched. There is no mention of adding at least some of the cocoa liquor after the conching step or during or after the liquefying phase of the conching step.

<CIT> discloses a method of manufacturing a chocolate product comprising mixing two ingredient mixtures. The first mixture comprises a dry paste of size reduced cocoa butter substitute and sugar, and the second mixture comprises refined cocoa liquor and lactose crystallised non-fat milk powder. The mixtures are then combined and conched. There is no mention of adding at least some of the cocoa liquor after the conching step or during or after the liquefying phase of the conching step.

<CIT> and <CIT> disclose a method of manufacturing a chocolate product comprising combining sugar and cocoa butter and minimal amounts of water, then refining and conching the mixture before adding cocoa liquor and milk powder, mixing, refining and further conching the mixture for <NUM> hours. There is no mention of adding at least some of the cocoa liquor during or after the liquefying phase of the conching step. There is a <NUM> hour conching step after the cocoa liquor is added; therefore, the cocoa liquor is not added after the conching step and there is no mention of adding at least some of the cocoa liquor after the conching step.

<CIT> discloses a method of manufacturing a chocolate product comprising adding the cocoa liquor at the start of the method. There is no mention of adding at least some of the cocoa liquor after the conching step or during or after the liquefying phase of the conching step.

<FIG> is a process flow diagram illustrating schematically a known batch process <NUM> for producing a milk chocolate. In the known batch process, chocolate ingredients including cocoa liquor <NUM>, sugar <NUM>, cocoa butter <NUM>, anhydrous milk fat (AMF) <NUM> and skimmed milk powder <NUM> are combined in a mixer <NUM> to form a chocolate ingredient mixture <NUM>. Other ingredients including flavouring, such as vanilla, may also be added to the chocolate ingredient mixture <NUM>. The chocolate ingredient mixture <NUM> is subject to a size-reduction process <NUM> before being conched <NUM>. In one known process, the chocolate ingredient mixture is refined to reduce particle size, with the chocolate ingredient mixture subject to a pre-refining stage and a main refining stage in a roll refiner. Conching <NUM> helps to further mix the size-reduced ingredient mixture 24a and develop the flavour, aroma and mouth feel of the chocolate in a known manner. The chocolate ingredient mixture 24a passes through a number of phases during conching. In an initial dry phase, the chocolate ingredient mixture is in powdery form, and the mixing coats the particles with fat. Air movement through the conche removes some moisture and volatile substances, which may give an acidic note to the flavour. The chocolate ingredient mixture subsequently transitions through a paste phase into a final liquid phase. Further ingredients may be added during conching. For example, the viscosity of the finished product can be adjusted by the addition of fats (such as further cocoa butter <NUM> and/or AMF <NUM>) and/or emulsifiers, such as soya lecithin <NUM>. Further flavouring can also be added depending on the intended use of the chocolate. The chocolate mass obtained using the known process is used in the formation of chocolate products which may be represented by solid chocolate tablets or bars as well as compounded or enrobed products such as chocolate coated wafers, chocolate-containing biscuits and the like. A similar process can be used to produce other types of chocolate by varying the ingredients used in the chocolate ingredient mixture as is known in the art. For example, to produce plain or dark chocolate the dairy ingredients may be omitted or reduced and different flavourings can be used.

All the solid materials, including cocoa liquor, are usually combined at the start of the chocolate making process and refined together so that the particle size of the non-fat cocoa solids is reduced, and the deleterious flavours in the cocoa liquor, such as acetic acid produced in the fermentation of the cocoa beans, is removed during the dry conching phase. However, the need to refine the cocoa liquor together with the other ingredients in the chocolate ingredient mixture limits the overall throughput of the process for a given batch size.

A further issue with the known process is that the presence of cocoa liquor <NUM> in the chocolate material mixture <NUM> is believed to be responsible for wear of the apparatus <NUM> when the mixture is being size-reduced. This is a particular issue where the mixture is refined using one or more roll refiners, where cocoa liquor causes wear of the refiner rolls.

It is desirable, therefore, to provide a process for the manufacture of chocolate which enables a higher yield for a given batch size whilst producing chocolate with broadly similar characteristics.

It is also desirable to provide a process for the manufacture of chocolate which results in less wear of the equipment used for size-reduction.

In a first aspect of the invention, there is provided a process for the manufacture of a chocolate product comprising;.

wherein the size-reduced chocolate ingredient mixture is conched and at least some of the cocoa liquor is added to the size-reduced chocolate ingredient mixture during one or more of the following steps:.

For the purposes of the present invention, the term cocoa liquor is defined as the material produced from cocoa beans after the cocoa shell has been removed and the beans milled or ground, and also includes mixtures of non-fat cocoa solids (including cocoa powder) mixed with a fat (which may be, for example, cocoa butter or a non-cocoa butter fat, or any combination thereof) to produce a reconstituted cocoa liquor.

In an embodiment, no sucrose or milk ingredient is added with or mixed with the cocoa liquor when it is added to the size-reduced chocolate ingredient mixture during step <NUM>), <NUM>) or <NUM>). In an embodiment, the cocoa liquor added to the size-reduced chocolate ingredient mixture in step <NUM>), <NUM>) or <NUM>) may be added with or mixed with a fat and/or emulsifier, while in other embodiments it is added substantially alone, with no other ingredients.

In some embodiments at least <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>%, <NUM>% or <NUM>% of the total amount of cocoa liquor is added during steps <NUM>), <NUM>) or <NUM>). Adding a majority of the cocoa liquor during steps <NUM>), <NUM>) or <NUM>), provides particularly stark advantages in manufacturing a chocolate product which has broadly similar characteristics as chocolate produced using known methods, whilst enabling significant cost reductions and enabling a higher yield for lower batch sizes.

The amount of non-fat cocoa solids in the cocoa liquor is preferably between <NUM> and <NUM> %wt. of the cocoa liquor, more preferably between <NUM> and <NUM> %wt. non-fat cocoa solids, or between <NUM> and <NUM> %wt. non-fat cocoa solids. The remaining fat in the cocoa liquor preferably comprises cocoa butter, but alternatively or additionally may comprise at least one other fat, such as a cocoa butter equivalent (CBE), a cocoa butter substitute (CBS), a vegetable fat, palm fat or the like, for example. In preferred embodiments the cocoa liquor is standard cocoa liquor comprising non-fat cocoa solids and cocoa butter, which may have up to <NUM>%wt. , <NUM>%wt. or up to <NUM>%wt. non-cocoa butter fat added.

It should be noted that the cocoa liquor may be added during step <NUM>) to the conche, but without conching the resultant mixture of the size-reduced chocolate ingredient mixture and cocoa liquor during either a dry or liquid phase of conching. The cocoa liquor and conched size-reduced chocolate ingredient mixture may simply be mixed in the conche without conching the final mixture. In such embodiments the conche is acting as a standard mixer for step <NUM>).

For step <NUM>), the cocoa liquor may be added to the sized reduced and conched chocolate ingredient mixture in a further mixing stage after conching. The further mixing stage may be carried out in a mixing tank.

The size reduced and conched chocolate ingredient mixture makes up the majority of the final chocolate product and may comprise at least <NUM>%, or at least <NUM>%, or at least <NUM>%, or at least <NUM>%, or at least <NUM>% of the final chocolate product.

Adding cocoa liquor to a chocolate ingredient mixture having at least <NUM> % wt. fat, after the liquefying phase of conching of the chocolate ingredient mixture has begun (or after conching), reduces wear on the conch, decreases energy use, and allows for increased yield, whilst surprisingly providing a final chocolate product which is substantially identical to one in which all of the ingredients are mixed and conched in known processes.

In a second aspect of the invention, there is provided a process for the manufacture of a chocolate product comprising;.

In the processes of the second aspect of the invention, size-reducing a chocolate ingredient mixture with no or little cocoa liquor, followed by addition of cocoa liquor (or further cocoa liquor) after conching the chocolate ingredient mixture, reduces energy usage and wear on the conch while surprisingly providing a chocolate product substantially identical to one in which all cocoa liquor is added to the conch. In the process of the second aspect of the invention the chocolate ingredient mixture may comprises no, or substantially no, cocoa liquor when the size-reduction step is carried out.

In an embodiment according to the second aspect of the invention, the cocoa liquor is added to the sized reduced and conched chocolate ingredient mixture in the conch at the end of the conching stage. Alternatively, the cocoa liquor can be added to the sized reduced and conched chocolate ingredient mixture in a further mixing stage after conching, which may be carried out in a mixing tank.

In an embodiment according to either of the first or second aspects of the invention, the size reduced chocolate ingredient mixture is extruded after conching and the cocoa liquor is added to the size-reduce chocolate during extrusion.

In an embodiment according to either of the first or second aspects of the invention, the cocoa liquor is subject to processing before being added to the size-reduced chocolate ingredient mixture.

In an embodiment according to either for the first or second aspects of the invention, the cocoa liquor is sieved prior to being added to the size-reduced chocolate ingredient mixture to remove particles above a given size. The cocoa liquor may be sieved to remove particles having a size of at least <NUM>, or at least <NUM>, or at least <NUM>, or at least <NUM>, or at least <NUM>, or at least <NUM>, or at least <NUM>.

In an embodiment according to either of the first or the second aspects of the invention, the cocoa liquor is size-reduced separately from the chocolate ingredient mixture prior to being added to the size-reduced chocolate ingredient mixture. The cocoa liquor may be size reduced to have a specific particle size distribution. The cocoa liquor may be size reduced to have a specific particle size distribution having a D90 value in the range of <NUM>-<NUM>. In an embodiment, size-reduction of the cocoa liquor is carried out using a ball mill. In an embodiment, size-reduction of the cocoa liquor comprises refining, e.g. using a <NUM>-roll or <NUM>-roll refiner.

In a third aspect of the invention, there is provided a process for the manufacture of a chocolate product comprising:.

Ball milling of the cocoa liquor followed by addition of the ball-milled cocoa liquor to the size-reduced chocolate ingredient mixture either during or after conching of the mixture, is believed to provide a chocolate product which is substantially identical to products made by known chocolate processes, whilst avoiding excessive wear on the machinery used to size-reduce the chocolate ingredient mixture and/or the conche, enabling energy reduction of the process, and ensuring maximum yield.

The ball milled cocoa liquor may be added to the size reduced chocolate ingredient mixture during conching. In an embodiment according to the third aspect of the invention, the ball milled cocoa liquor is added to the size-reduced chocolate ingredient mixture during a liquifying phase of conching. In a further embodiment according to the third aspect of the invention, the ball milled cocoa liquor is added to the size-reduced chocolate ingredient mixture both during a dry phase and during a liquifying phase of conching. In a still further embodiment according to the third aspect of the invention, the ball milled cocoa liquor is added to the size-reduced chocolate ingredient mixture at the end of or after conching. The ball milled cocoa liquor may be added to the size reduced chocolate ingredient mixture in the conche at the end of the conching process. In an alternative embodiment, the ball milled cocoa liquor is added to the size reduced and conched chocolate ingredient mixture in a separate mixing stage after conching, which separate mixing stage may be carried out in a mixing tank.

In the process according to any of the first, second or third aspects of the invention, size-reduction of the chocolate ingredient mixture may comprise grinding, milling, or refining of the chocolate ingredient mixture. In an embodiment, size-reduction of the chocolate ingredient mixture comprises refining and may be carried out using a roll refiner, such as a <NUM>-roll or <NUM>-roll refiner. The size reduction process may include a pre-refining stage.

In the process according to any of the first, second or third aspects of the invention, the chocolate ingredient mixture may comprise at least two ingredients selected from the group comprising a sweetener, a fat, a milk ingredient, cocoa butter (or any equivalent or substitute thereof) and flavouring.

In some embodiments the chocolate ingredient mixture may comprise sugar and/or other sweetener, cocoa butter or cocoa butter substitute, and AMF. The chocolate ingredient mixture may further comprise any one or more of the group comprising skimmed milk; sweet whey powder; and flavouring.

The process according to any of the first, second and third aspects of the invention may comprise adding further ingredients to the size-reduced chocolate ingredient mixture during conching including any one of more selected from the group comprising AMF; lecithin, such as soya lecithin, and/or other emulsifier; and flavouring.

In the process according to any of the first, second and third aspects of the invention, the coca liquor may consist substantially exclusively of cocoa liquor prior to addition to the chocolate ingredient mixture.

The process according to any of the first, second or third aspects of the invention may comprise tempering the chocolate mass after conching.

The process according to any of the first, second or third aspects of the invention may comprise extruding or moulding of the chocolate mass, which may be carried out after an optional tempering step.

The process according to any of the first, second and third aspects of the invention may be a batch process.

In order that the invention may be more clearly understood, one or more embodiments thereof will now be described, by way of example only, with reference to the remaining drawings, of which:.

Throughout this specification the term "chocolate" or "chocolate product" includes all chocolate or chocolate-like compositions with a fat phase or fat-like composition. The term is intended, for example, to include standardized and non-standardized chocolates, including dark chocolate, baking chocolate, milk chocolate, sweet chocolate, semi-sweet chocolate, buttermilk chocolate, skim-milk chocolate, mixed dairy product chocolate, low fat chocolate, aerated chocolates, compound coatings, non-standardized chocolates and chocolate-like compositions, unless specifically identified otherwise. Chocolate-like products include, for example, imitation chocolate that has cocoa butter replaced with other fats.

Throughout this specification, the term "cocoa liquor" should be understood as including liquor produced by the pressing, grinding and/or crushing of cocoa nibs, as well as liquor produced by pasting non-fat cocoa solids, such as cocoa powder, with cocoa butter and/or confectionery fat substitute for cocoa butter.

<FIG> illustrates schematically an embodiment of a process <NUM>' for manufacture of a chocolate product according to aspects of the invention. The process <NUM>' is similar to the known process <NUM> described above, except that the cocoa liquor <NUM> is not included in the chocolate ingredient mixture <NUM>' which is subjected to a size-reduction step <NUM> in a mixer/refiner. Instead, the cocoa liquor <NUM> is added to the size-reduced chocolate ingredient mixture 24a' subsequent to the size-reduction step <NUM>. After refining, the chocolate ingredient mixture 24a' is conched and, as is illustrated in <FIG>, the cocoa liquor <NUM> may be added to the size-reduced chocolate ingredient mixture 12a' in the conche, during or after the liquefying phase of conching, or it may be added to the size-reduced chocolate ingredient mixture 24a' after conching. Where the cocoa liquor <NUM> is added after conching, it may be combined with the size reduced and conched chocolate ingredient mixture 24b' in a separate mixing stage <NUM> which may be carried out in a mixing tank.

Cocoa liquor <NUM> has traditionally been included in the chocolate ingredient mixture at the start of the chocolate making process so that it is passed through the refiner <NUM> together with the majority of the other solids to reduce particle size and then conched <NUM>, including during the dry phase of conching, in the belief that this was necessary to remove deleterious flavours in the cocoa liquor. However, the applicant has found that chocolate having similar characteristics and acceptable quality in terms of appearance, taste, aroma and mouth feel can be produced if the cocoa liquor <NUM> is added after the size-reduction step <NUM> and after the dry phase of conching. Removing the cocoa liquor <NUM> from the chocolate ingredient mixture <NUM>' processed in the mixer/refiner <NUM> enables a higher yield in the finished cholate <NUM> to be produced for a given batch size of ingredients processed in the mixer/refiner <NUM>. This is illustrated in <FIG>, which compares graphically the amount finished chocolate <NUM>, <NUM>' produced for a batch size of <NUM> of chocolate ingredient mixture <NUM>, <NUM>' using the known process <NUM> and the modified process <NUM>' according to the invention. In the know process <NUM> on the left, a chocolate ingredient mixture <NUM> includes cocoa liquor <NUM>. A batch of <NUM> of this mixture <NUM> is refined and then conched <NUM> to produce a finished chocolate product <NUM>. In the modified process <NUM>' in accordance with aspects of the present invention shown on the right, the chocolate ingredient mixture <NUM>' subjected to the size reduction process <NUM> does not include cocoa liquor <NUM>. This creates additional space so that the amounts of the other ingredients can be increased proportionally to maintain the same batch size of <NUM> for processing in the mixer/refiner <NUM>. The refined mixture 24a' is subsequently conched <NUM> and the cocoa liquor <NUM> added, either during or after the liquefying phase of conching. The amount of cocoa liquor <NUM> added may be increased proportionally with the other ingredients to maintain the same overall recipe. The use of increased amounts of the chocolate ingredients <NUM>, <NUM>, <NUM>, <NUM> in the mixture <NUM>' which is subjected to the size reduction process <NUM>, as well as the corresponding increased amount of cocoa liquor <NUM> subsequently added, results in an increased amount of finished chocolate <NUM>' in comparison to the known process. Tests by the applicant indicate that for a batch size of <NUM> of the chocolate ingredient mixture size reduced in a <NUM>-roll refiner and conched in a <NUM> conche, an increase of around of <NUM> % in the finished chocolate yield is achievable using the modified process <NUM>' according to aspects of the invention in comparison to the known process <NUM> in which the cocoa liquor is refined and/or conched together with the other dry ingredients.

A further advantage of the modified processes <NUM>' according to aspects of the invention is that the absence of cocoa liquor <NUM> reduces wear on the apparatus <NUM> used for size reduction of the chocolate ingredient mixture <NUM>'. This is particularly advantageous where the chocolate ingredient mixture is refined using a roll refiner. In this regard, it has been found to be particularly advantageous if the chocolate ingredient mixture <NUM>' without cocoa liquor has a fat content of more than <NUM> % wt. , or more than <NUM> % wt. , or more than <NUM> % wt. , as the fat liquefies and coats the other ingredients, avoiding friction as much as possible, during size-reduction.

The cocoa liquor may <NUM> may be added to the size-reduced chocolate ingredient mixture 24a' in the conche during the liquid phase. Addition of the cocoa liquor can also be split, with some cocoa liquor <NUM> being added in the dry phase and some in the liquid phase, as long as at least <NUM>% of the cocoa liquor is added during the liquid phase; or with some cocoa liquor <NUM> being added in the liquid phase and some either at the end of conching or after conching.

In alternative embodiments, all of the cocoa liquor <NUM> is added to the chocolate ingredient mixture after conching. In this case, the cocoa liquor <NUM> can be added in the conche but after conching has been substantially completed. Alternatively, the cocoa liquor can be added to the conched chocolate ingredient mixture 24b' after it has left the conche in a further mixing stage <NUM>. The further mixing stage could be carried out in a mixing tank, for example. In a still further alternative embodiment, the conched mixture 24b' is extruded and the cocoa liquor <NUM> is added either just prior to the mixture entering the extruder or whilst the mixture is in the extruder. In this embodiment, the extruder may be a screw extruder.

It is also within the scope of the invention that some cocoa liquor is added to the size-reduced chocolate ingredient mixture in the conche during the liquefying or later phases of conching and some after conching.

The cocoa liquor <NUM> added to the chocolate ingredient mixture may be processed and may be stripped to remove unwanted acidic volatiles and flavours.

Whilst cocoa liquor <NUM> used in the known process <NUM> generally has a relatively small particle size, around <NUM>-<NUM>, it has been found to be advantageous to sieve the cocoa liquor <NUM> prior to adding it to the size-reduced chocolate ingredient mixture 24a', 24b'. This removes particles at or above a given size depending on the sieve used and reduces the chances of larger cocoa particles in the cocoa liquor being present and detectable the finished cholate product <NUM>'. In embodiments, the cocoa liquor <NUM> is sieved to remove particles having a size of at least <NUM>, or at least <NUM>, or at least <NUM>, or at least <NUM>, or at least <NUM>, or at least <NUM>, or at least <NUM>.

As an alternative to sieving or in addition, the coca liquor <NUM> may subjected to a size reduction operation separately from the chocolate ingredient mixture <NUM>' before being added. In an embodiment, the cocoa liquor <NUM> is size-reduced to have a particle size distribution with a D90 value in the range of <NUM>-<NUM>. In a particularly advantageous embodiment, the cocoa liquor <NUM> is ball milled to reduce particle size.

The chocolate mass produced after conching may be subject to further optional processing, such as tempering.

The chocolate mass obtained using the processes of the invention, whether subject to optional processing steps after conching or not, can be used in the formation of chocolate products which may be represented by solid chocolate tablets or bars as well as compounded or enrobed products such as chocolate coated wafers, chocolate-containing biscuits and the like. The chocolate mass may be formed into chocolate product by any of the known means including moulding, extrusion and the like.

As part of a trial, two batches of chocolate were produced using the known, standard process <NUM> for comparison with samples made using the modified process <NUM>' according to aspects of the invention. For each standard batch, a chocolate ingredient mixture <NUM> was prepared from the following ingredients:.

Refining - Flakes were prepared from the above components using a <NUM>-roll refiner to produce a target particle size of <NUM> +/- <NUM>.

Conching - Conching was carried out in a <NUM> Elk (RTM) conche using <NUM> of the refined chocolate ingredient mixture flakes. The following additions were made during conching:.

For the both standard batches, the conche was kept open throughout the dry phase and active conching of the cycle and then closed from the liquid phase till the end.

Initially, three samples were made using the modified process <NUM>' in accordance with the invention, each using the same basic chocolate ingredient mixture <NUM>' made from the following ingredients:.

In the modified chocolate ingredient mixture <NUM>', the amounts of cocoa butter and anhydrous milk fat were modified to maintain a similar fat content to that of the chocolate ingredient mixture in the comparative sample. Those skilled in the art will understand that the fat content of the chocolate ingredient mixture can be modified for efficient processing in a roll refiner.

Conching - Conching of the size reduced modified chocolate ingredient mixture was carried out in a <NUM> Elk (RTM) conche using <NUM> of the refined flakes of chocolate ingredient mixture <NUM>'.

For all examples of the invention, the cocoa liquor <NUM> was passed through a <NUM> sieve before being added.

For all examples of the invention, the conche was kept open throughout the dry phase and active conching of the cycle and then closed from the liquid phase till the end.

During conching for all examples of the invention, the additions in the dry phase are added in a way to ensure that the phase is kept dry enough (also not too dry, to avoid formation of agglomerates) and an early collapse of the mass is avoided. This helps to prevent a non-homogenous and inefficient mixing of the mass during conching and a significant increase in viscosity in the finished chocolate.

In each of the initial three examples of the invention, the cocoa liquor was added in a different phase during or after conching as set out below.

Addition of cocoa liquor was split, with a first addition of <NUM>% of the cocoa liquor in the dry phase and a second addition of the remaining <NUM>% 0f the cocoa liquor in the liquid phase as set out in the table below:.

Cocoa liquor was added during the liquid phase of conching only:.

Cocoa liquor was added to the conche only during a final stage after conching was substantially complete or afte the conched chocolate ingredient mixture was removed from the conche and placed in a separate mixer:.

Sensory analysis of the finished chocolate <NUM>, <NUM>' was carried out in a qualitative round table. A few minor differences were perceived between the three examples of the invention and the comparative examples, but were generally within an acceptable range.

Overall differences were not significant and all the inventive examples were within reasonable limits of standard production variability. Accordingly, it was concluded that the point at which the cocoa liquor is added during the liquefying phase or at the end of conching, has little impact on the overall sensory profile of the finished chocolate mass.

In order to assess the effect of processing the cocoa liquor to reduce particle size prior to addition to the size-reduced chocolate ingredient mixture <NUM>', the three inventive examples above were repeated but using a cocoa liquor ball milled to a particle size distribution (D90) in the range of <NUM>-<NUM> prior to being added to the refined chocolate ingredient mixture <NUM>'.

The further examples were assessed in a round table sensory evaluation. All were determined to be acceptable and found to have significant depth of flavour, substantially matching chocolate produced by known processes.

Claim 1:
A process for the manufacture of a chocolate product comprising;
a. performing a size-reduction step on a chocolate ingredient mixture comprising no non-fat cocoa solids, and comprising more than <NUM> % wt. fat; and
b. adding cocoa liquor to the size-reduced chocolate ingredient mixture to form a chocolate mass.
wherein the size-reduced chocolate ingredient mixture is conched and at least some of the total amount of cocoa liquor is added to the size-reduced chocolate ingredient mixture during one or more of the following steps:
<NUM>) a liquefying phase of conching the size-reduced chocolate ingredient mixture;
<NUM>) later than a liquefying phase of conching the size-reduced chocolate ingredient mixture; and
<NUM>) after conching the size-reduced chocolate ingredient mixture.