Do more for less in chocolate manufacturing

Palsgaard® AMP 4455

Dreaming of the perfect chocolate?

It’s a chocolate manufacturer’s dream: cost-effective and stable control over the viscosity of any type of chocolate – regular or low fat – without the taste or odour downsides of lecithin. Now there’s a new production “tool” that can make all of this possible.

Far lower dosages – same effect

Developed as a powerful alternative to lecithin, Palsgaard® AMP 4455 is a state-of-the-art ammonium phosphatide chocolate emulsifier (also known as AMP, Emulsifier YN or E442).

Palsgaard® AMP 4455 has the remarkable ability to out-perform lecithin without the usual downsides of lecithin and at far lower dosages. For chocolate manufacturers eager to explore new limits, Palsgaard has come up with a compelling “more for less” solution that eases production and saves costs.

Outperforming lecithin

Lecithin, the much-used cornerstone of chocolates around the world, has been included in chocolate recipes for more than 60 years. In that time, it has served its purpose well, acting as a functional and reasonably efficient ingredient when it comes to adjusting flow properties and reducing fat content in chocolate.

But it’s not without its drawbacks. For example, the soy-based variety used in the confectionery industry is at the mercy of natural variations in the bean harvests from year to year and region to region. On the one hand, this means fluctuations in supply and prices – adding to the difficulties for manufacturers already dealing with the ups and downs of the cocoa bean market. On the other, the performance of lecithin is highly dependent upon the purity and composition of its raw materials.

Palsgaard® AMP 4455 (E442) doesn’t suffer from such difficulties. The newly developed chocolate emulsifier pro-duces properties in chocolate never seen before. It’s based on highly consistent and obtainable raw materials, so its quality isn’t at the mercy of Mother Nature. And perhaps best of all, Palsgaard® AMP 4455 has been documented to outperform normal types of lecithin used by the chocolate industry at all dosage levels – both when producing choco-late and compound chocolate.

Do more for lesswith Palsgaard® AMP 4455 chocolate emulsifier

More for less

Using less raw material to obtain the same result is a key aim for any manufacturer whether they use soy, sunflower or rapeseed lecithin. And this is precisely where Palsgaard® AMP 4455 has its most striking advantage. In fact, it’s pos-sible to use as little as 40 percent of the dosage required with any of the lecithin types mentioned above. Clearly, any dosage reduction approaching such levels will dramatically decrease total consumption of emulsifiers.

Of course, the actual required dosage depends on a number of factors, including the chocolate system (milk, dark, white or crumb chocolate, for example) and the current total fat content of the chocolate produced. For many manufactur-ers, a level approaching half the current dosage levels will be more realistic. But even Palsgaard® AMP 4455’s most extreme reduction achievements have been consistently demonstrated in trials with chocolates using 0.4% and 0.5% lecithin dosages.

Dramatic dosage reductions

Picking a winner: AMP

AMP has been used by the chocolate industry as a chocolate emulsifier since the late 1950’s, and is well known as a strong alternative to lecithin types such as GMO and non-GMO soy lecithin, sunflower lecithin and rapeseed lecithin.

Palsgaard identified AMP many years ago as potentially the best and most functional viscosity-reducing chocolate emulsifier. And we’ve been unrelenting in our efforts to realise this potential, working closely with customers with very different chocolate systems and in different parts of the world to constantly re-approach and refine every aspect of our AMPs.

Avoid the “Thickening Effect”

Today, most manufacturers use soy lecithin, sunflower lecithin or rapeseed lecithin as their chocolate emulsifiers. All can potentially cause a problem well-known to produc-tion managers throughout the chocolate industry, known at Palsgaard as the “Thickening Effect”.

Occurring at dosages of around 0.4 to 0.5 percent, the Thickening Effect describes an increase in yield value that can slow down production and place both the quality and the cost-effectiveness of the final product at risk. In fact, many chocolate recipes may have been formulated with the Thickening Effect in mind, and lecithin has, therefore, dic-tated a natural barrier to product development.

Palsgaard® AMP 4455 doesn’t encounter this problem. Instead, manufacturers can dose up to 1 percent Palsgaard® AMP 4455 to achieve the desired viscosity reduction. And it’s this unique ability that opens the door to new, low-fat, low- calorie and low-cost recipes. With Palsgaard® AMP 4455, you now have a unique tool to explore the limits of cost reduction while maintaining the quality of your chocolate.

Neutral taste

Lecithin is well known for imparting off-flavours – an unwel-come effect that varies from batch to batch and from supplier to supplier. Palsgaard® AMP 4455, however, is designed to be a taste-neutral product, enabling it to be used at high dosages in applications sensitive to off-flavours such as crumb chocolate with its low content of cocoa solids, white chocolate, or confectionary spreads.

Lecithin-beating functionality

Viscosity Reducing Power (VRP) for improved batch-to-batch stability

Production costs are also closely tied to your ability to achieve and maintain consistent product quality, producing batch after batch of your company’s top products and securing customer loyalty.

Palsgaard has a unique approach to ensuring func-tional stability in chocolate: no Palsgaard® AMP 4455 emulsifier batch is supplied without undergoing ex-tensive testing in chocolate. Called the VRP method, this ensures every batch meets the specified vis-cosity reductions to produce the same rheological results every time. Thanks to VRP, no unfavorable recipe adjustments are needed.

Non-GMO and non-allergenic

An increasing number of chocolate manufacturers choose non-GMO ingredients for their chocolate recipes to closely align with consumer and regulatory concerns. Palsgaard® AMP 4455, which is based on raw materials of a non-GMO origin and can be classified as both non-GMO and non-aller-genic, neatly and cost-effectively answers these concerns.

Microbiologically safe

Chocolate manufacturers also face the challenge of keep-ing production equipment clean and the chocolate free of microbiological organisms such as E. coli and salmonella.

Here too, Palsgaard® AMP 4455 is far superior to lecithin. In fact, the new emulsifier has been specifically developed to provide a high degree of safety against such pathogens, and all batches of Palsgaard® AMP 4455 are produced in hygienic, sealed machinery at temperatures where it’s im-possible for microorganisms to survive. In the event of con-tamination further along the supply chain, inoculation tests confirm that all microorganism activity would cease in less than a week.

Practically unlimited supply

Palsgaard® AMP 4455 is primarily manufactured using a combination of refined and deodorised sunflower oil and glycerine, making it a 100%-vegetable based product. Sun-flower oil is one of the major vegetable oils on the world market, which ensures a stable supply and minimises price variations. At the same time, all the raw materials used are Kosher and Halal-certified.

A closer fit to market needs

Palsgaard® AMP 4455 is a showcase of compliance with widely demanded manufacturer and consumer preferences, offering the following important attributes:

• 100% vegetable-based (sunflower oil and glycerine in stable supply)

• Non-GMO, non-soy

• Contains no allergens

• Kosher and Halal certifications available

• Proven low risk of microbiological contamination

• AMP’s proven track record in chocolate

• Pumpable at room temperature for easy handling

The safest choice for the future of food

Profits under pressure

With the prices of cocoa butter and other cocoa ingredients steadily climbing, and a high degree of uncertainty about the future, the chocolate industry’s profit margins are squeezed more tightly than ever before. Management is asking wheth-er all possible potential savings have been identified in their company’s recipes. And they’re keen to explore new cost-saving opportunities.

Palsgaard® AMP 4455 gives production managers a new and highly effective avenue to explore potential savings and expand profit margins.

This new chocolate emulsifier meets or exceeds the ef-fects of lecithin at vastly reduced dosages. And it’s enabling chocolate-producers to take back control of their costs.

Put the squeeze on costs

Palsgaard® AMP 4455 is just as easy to use as lecithin, but outperforms it in reducing the chocolate’s plastic viscosity – using as little as 40 percent of the normally applied dosage.

Out-saving lecithin

Using lecithin in chocolate at a dosage of around 0.4 percent normally provides cocoa butter or vegetable fat savings of around 4 percent. At the same dosage level, however, Palsgaard® AMP 4455 can extend these savings by an additional 2-3 percent to create a total potential saving of 6-7 percent.

While actual savings may vary over time due to fluctuating raw material prices and the different qualities of ingredients in use, reducing cocoa butter usage by an additional 2-3 percent could be expected to translate to savings of EUR 1.0-1.75 million per 10,000 tons of produced chocolate. And that’s a difference management will certainly notice.

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Milk chocolate 31% total fat

Making the switchis easy

Using Palsgaard® AMP 4455 means no undesired increase in yield value (thickening effect) at higher dosage levels which enables efficient manufacturing of very low fat chocolates.

Driving savings higher

For special applications where the taste profile isn’t a critical parameter – as with chocolate drops used in cookies, or chocolate used for enrobing a cake, countlines or biscuits – there’s even more flexibility to use less cocoa butter. Here, Palsgaard® AMP 4455 can take cost savings far beyond the limits of lecithin, continuing to reduce the viscosity of the chocolate even at dosages of 0.6 or 0.7 percent – still without encountering the thickening effect.

At these dosage levels, increased savings of around 4-5 percent can be made on cocoa butter, translating to total cocoa butter savings of 8-9 percent when the traditional lecithin saving is taken into account.

With properties like these, Palsgaard® AMP 4455 enables new product development or sharpening of “old” recipes in ways never possible before.

Easy reformulation

If you have a long list of chocolate recipes, switching to AMP as an emulsifier may seem like a time-consuming and dif-ficult task. In fact, the reverse is true. A good way to begin is to simply set the Palsgaard® AMP 4455 dosage to half of the current lecithin dosage, and see if this produces the same rheological properties of the chocolate. Only a few rheological tests and dosage adjustments should be needed to reach the target rheology.

Delivery details

Palsgaard® AMP 4455 can be supplied in 200 kg steel drums, 900 kg IBC containers or as bulk deliveries. The most cost-effective solution – bulk deliveries of up to 24 tons – only requires a storage tank to be ready when offloading the product.

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Yield Value (Pa)

Dosage (%)

Palsgaard® AMP 4455

Lecithin

Milk chocolate 31% total fat

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Sharpen your recipes with Palsgaard

we are e x p e r t s in

emulsif iers and stabilizers for bakery,

confectionery, dairy, ice cream, margarine and fine foods - and we

are happy to share our expertise. our company values can be defined

in just three words: loyalty, responsibility and commitment. we aim to be the preferred partner

and supplier of quality products, application service and know- how to regional and mu l t i - na t i ona l food companies. to Palsgaard

l o y a l t y means that we act as a reliable and honourable business partner for our customers. we treat information confidentially and know

how to keep a business secret. to Palsgaard r e s p o n s i b i l i t y means caring about the environment and being aware of our corporate social responsibility; we have a goal to be CO2 neutral by 2020 and are members of SEDEX and RSPO. to Palsgaard c o m m i t m e n t means we are dedicated to getting the best results for our customers’ products - to the benefit of their customers. we care about our employees and have a declared aim that Palsgaard must be a pleasant place to work. Palsgaard we know that our most important resource is the know-how and dedicat ion found in our employees. Heart we are committed to getting the best results with our products in our pilot plants

and in your facilities. Working at Palsgaard we don’t sell standard solutions - we start with your needs.

Palsgaard - Heart Working People® heart work is the best way to achieve success - let us help you

get it. our products are produced according to the strictest quality criteria. we are experts

in emulsifiers and stabilizers and we are happy to share our

expertise with you. let our pilot plants help you shorten

the step between idea and your new product.

heart work is the best way to succeed

- let us help you do

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A cost-saving yet functional recipe is a competitive advantage that should be re-visited regularly for a “service check”. Yet not all chocolate manufacturers have conducted such a check – and many are missing out on savings made possible by new advances such as Palsgaard® AMP 4455.

We always recommend our customers to check their long-established chocolate recipes, focusing on exactly how much cocoa butter is actually needed for the specific appli-cation and revealing any hidden cost-saving opportunities.

Palsgaard has many years of experience with identifying optimal recipe settings. Our application specialists are always ready to help you find hidden savings, boost your competitiveness and secure a healthy bottom line. Palsgaard® AMP 4455 may be the tool to help you achieve exactly that.

If you’re interested in learning how Palsgaard’s chocolate emulsifiers can help with your day-to-day production chal-lenges or how the new emulsifier can create more cost-effective recipes, visit www.palsgaard.com to locate your local Palsgaard office.

Palsgaard A/SDK-7130 Juelsminde, DenmarkPhone +45 76 82 76 82Fax +45 76 82 76 83direct@palsgaard.dkwww.palsgaard.com