Production Process – Kit kat Bar


How are Kit kat Bar made?

Chocolate Wafer plant produces wafer and chocolates of different variety. The production is line type. Chocolate wafer is wheat flour-based product. The other ingredients are sugar, starch powder, water, lecithin, vegetable fat, compound milk, RBD oil, citric acid, flavor and color.

The processes involved in this plant are:

1. Batter preparation

Batter is prepared by mixing wheat flour, salt, sugar, gluten, lecithin, sunflower oil, starch powderand soda at required proportion and moistening with water. It is mixed for about 12 minutes to obtain homogeneous mixture.

batter preparation

2. Cream preparation

Cream is prepared by mixing grinded sugar, sunflower oil, lecithin, caramel, Vanaspati ghee, SMP and breakdown product of wafer, after being grinded in powered form and chocolate flavor in required cream mixtureproportion. It is mixed for 20 minutes.

3. Chocolate preparation

Compound milk is melted with oil at about 55 0C and mixed uniformly with cocoa powder, vegetable ghee, oil and milk at the same temperature.

 

4. Preparation of sheet

The preparation of the sheet is done in the oven. The oven consists of

  1. Heavy Die
  2. Heating Source and Nozzle
  3. Gas flowing pipe
  4. Heavy Die Conveyer
  5. Motor
  6. Gear Reduction
  7. Pump for feeding the chocolate

The batter is pumped into a revolving Die where batter is sheeted and baked at the same time. Baking is done at the temperature around 160 0C for 160 sec. the average length of sheet is 465

sheet preparation

mm, breadth is 287 mm respectively and thickness is 2-3 mm. there are 36 Dies. The sheets are then cooled.

5. Creaming

The sheets are collected and creamed. Three such creamed sheets are placed one over the other and passed through pressing machine to form book. The thickness of book is about 9 mm. the average weight of creamed sheet is 350 g.

creaming machine

6. Cutting

The books are collected and wire cutting is done to desired length and breadth of 115 mm and 17 mm respectively. From a book about 68 biscuits can be prepared. Average weight of 1 biscuit is about 5.3 gm.

cutting machine

7. Chocolate enrobing

The biscuit is now collected, arranged on moving conveyor where it get enrobed with chocolate. The chocolate liquid is dripped from the fine hole of around 1-2mm in tube like structure. In this section the temperature of the enrobed biscuit is in between 40-50 degree C. Excess chocolate is blown by blower. Melted chocolate is continuously pumped over the biscuit by motor.

chocolate enrobing

8. Cooling

Then the enrobed biscuit is cooled in AC maintained system at 8-10 0C. Cooling time is 10 minutes. Cooling time is maintained according to the environment condition.

cooling machine

Refrigeration cycle is used to decrease the temperature of the air.

Air conditioners refrigeration cycle use the same cycle of compression, condensation, expansion, and evaporation in a closed circuit. The same refrigerant is utilized to move the heat from one area, to cool this area, and to drive out this heat in another area.

  • The refrigerant drives into the compressor as a low-pressure gas, it is compressed and then moves out of the compressor as a high-pressure gas.
  • The gas then flood to the condenser. Here the gas condenses to a liquid, and comports its heat to the outside air.
  • The liquid then shift to the expansion valve under high pressure. This valve limits the flow of the fluid, and lowers its pressure as it leaves the expansion valve.
  • The low-pressure liquid then moves to the evaporator, where heat from the inside air is absorbed and transform it from a liquid to a gas.
  • As a hot low-pressure gas, the refrigerant moves to the compressor where the whole cycle is repeated.

 

9. Packaging

The chocolate enrobed biscuits are collected and packaged and batch coded. Then they are filled in jars or pouches. The jars and pouches are then filled in cartoon and taped.

 

Read also : How cheese balls are made?

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