Program Schedule
PMCA'a 59th Annual Technical Production Conference
April 11-13, 2005
Hershey Lodge and Convention Center, Hershey, Pa.
Monday, April 11, 2005
Session led by moderator Michael Ferraro, Retired, Godiva Chocolate
BACK TO BASICS – CHOCOLATE MOULDING
The session will include a look at the historical perspective of Chocolate Moulding and an overview of the five generally recognized methods (solid, classic shell, cooled punch, one shot and hollow) as well as variations on these methods and the common characteristics of moulded products. Several speakers will participate in the session which will include product and equipment samples as well as video demonstrations. Once completed, the Back to Basics series, in its published form of the Proceedings, will provide an educational and training resource in confectionery technology, available to members of the association and others in the industry.
CHOCOLATE MOULDING - INTRODUCTION AND HISTORY
Michael Ferraro, Retired, Godiva Chocolate
The opening remarks will provide some insight on the history of Chocolate Moulding, from a rich liquid
to the first solid bar. The benefits of moulded products will be discussed as well as a brief comparison of the characteristics of moulded articles, to those created by enrobing or panning. An overview of common moulding processes will be provided as well an introduction to some of the latest processes and newest materials used for moulds.
DESIGNING AND DEVELOPING CHOCOLATE MOULDS
Dr. Paul M. Harbecke, Consultant, agathon GmbH & Co. KG
This presentation will discuss the development of chocolate moulds including the design of the impression, design of the mould, how moulds are actually made once the design is complete, types and treatment of the materials used, cleaning and storage of moulds, life expectancy and how to determine the maximum volume of a mould.
FORMULATIONS – COATING SELECTION FOR MOULDING APPLICATIONS
John J. Urbanski, VP – Technical Sales and Services, Wilbur Chocolate Company
This presentation will look at the factors affecting the selection of coatings for various moulding applications (solid, hollow, shell, one-shot and frozen cone) including viscosity, total fat content, type of fat, emulsifiers and compound fat systems. A discussion of the typical coating applications, including dipping and enrobing will also be provided.
CHOCOLATE MOULDING – SOUP TO NUTS
Graham Nice
This session will cover the sequence of steps performed in the moulding process “from soup to nuts”. Plant types, designs and forming technologies will be addressed. Specifically, information on mould conditioning (heating), depositing, vibrating (shaking or tapping) will be presented.
COOLING & DE-MOULDING
David Cruickshank, Chocolate Development Manager, Cadbury Trebor Bassett
Taking an in-depth look at the final stages of the moulding process, this presentation will focus on the cooling of moulded chocolate products and de-moulding. The functions of cooling (to remove specific and latent heat, contracting the chocolate so it releases cleanly and freely, and to produce a stable and attractive product) will be addressed. Other product considerations such as crystal growth and morphology, recipes and plant considerations will be reviewed. The presentation will conclude with a look at other technologies such as radiant cooling and finally a review of the de-moulding process.
Tuesday, April 12, 2005
Sessions led by moderators John Cooke, Cherrydale Farms & Judy Cooley, The Hershey Company Corp.
PMCA COMMITTEE UPDATES
Adrian Timms, Senior Staff Scientist, The Hershey Company Corporation, Chairman, PMCA Research Committee
An overview of the activities of the Association’s Research committee to include the Chairman transition, current fellowship and grant in aid programs, joint science symposium, research library and website developments.
Dennis Zak, Consultant, TMResource, Chairman, PMCA Education and Learning Committee
An update on the recent developments and activities of the Education and Learning committee will be highlighted including the revised mission, current short course schedule, cooperative learning programs with other associations and organizations, newly branded course materials and participation in the short course survey.
REGULATORY UPDATE FOR THE CONFECTIONERY INDUSTRY
Alison Reich Bodor, Vice President Regulatory and Technical Affairs, National Confectioners Association
In 2005 confectionery companies must implement recordkeeping systems to track ingredients throughout the manufacturing process as part of the final food security regulation issued by FDA in accordance with the Bioterrorism Act of 2002. The regulation requires establishments that manufacture, distribute, or import food to identify the immediate previous sources and the immediate subsequent recipients of food. Learn more about this regulation and other regulatory developments, including allergen labeling and a possible revision to FDA’s guidance document on lead in candy that will affect confectioners in 2005.
THE BIOTERRORISM ACT OF 2002 AND YOUR COMPANY – IMPLEMENTING CONTROL SYSTEMS AND SUPPORTING PRODUCTION CONTROL
Russ Pierce, President, GlobalReact
Successful implementation and management of the Bioterrorism Requirements Systems Process is critical for company’s to protect the world’s food supply. This presentation will address the factors of Control, Data Collection, Quick Response Reporting and Calculating Return on Investment of the Bioterror Capital Projects. Specific highlights will include Lot Tracking, RFID Technology and meeting the 4-6 hour response time requirements.
EMPIRICAL MODELS FOR PREDICTING SUGAR CRYSTALLIZATION IN CONFECTIONS
Dr. Richard W. Hartel, Professor of Food Engineering, University of Wisconsin-Madison, in conjunction with Patricia (Ryan) Lenz, General Mills
In some confections, sugar crystals are desired, whereas in other confections, their presence is a quality defect. The amount of sugar crystals in grained confections and the onset of graining during storage of
ungrained confections are related to the relative ratios of sucrose and corn syrup, among other factors. Fundamental and empirical models for predicting sugar crystallization in grained (fondant) and ungrained (caramel and jelly) candies will be presented.
2005 DIETARY GUIDELINES FOR AMERICANS
David Joy, Partner, Keller & Heckman LLP
A brief history of the USDA/HHS Dietary Guidelines will be mentioned followed by a more in-depth discussion surrounding the new guidelines and their expected impact on the public. The obesity issue, and how it will need to be addressed by all food manufacturers, will be discussed along with how these guidelines may impact individual eating patterns, government policies, regulations, school lunch programs and food labeling. An emphasis on the impact to confectionery companies as well as Key findings from the 2005 Advisory Committee will also be presented.
MICROSCOPY AS A TOOL IN QA AND PRODUCT DEVELOPMENT
Kathy Groves, Microscopy Consultant, Leatherhead Food International, in conjunction with, Dave Stumpf, The Hershey Company Corporation
Customer complaints or product failure need to be dealt with quickly to protect confidence in the product, brand and confectionery industry as a whole. It is very much in the food industry’s interest to take contamination and quality issues seriously and to establish where or why the contaminant has arisen. This presentation will show how microscopy is used as the first step in identifying the causes behind QA issues for physical contaminants. Live light microscopy will be included to show examples of contaminating fragments as well as structures of various confections. The types of microscopes and their applications will also be presented.
EQUIPMENT AND TECHNOLOGY IN THE HARD CANDY INDUSTRY
Jack Collins, President, Collins Resources, Inc.
The evolution of the various types of equipment used in the hard candy industry will be explored. The presenter will share his wealth of experience in this area, including a look at some individual case studies and their impact on the evolution of equipment, processes and specific candy formulations. In
particular, the development and evolution of batch cookers, continuous cookers, forming and feeding equipment, pulling technology and wrapping equipment will be presented. Some speculation into the persistent problems that continue to seek a solution, via the next generation of manufacturing processes, will also be explored.
LEAN MANUFACTURING
Robert Woelfling, Vice President, Manufacturing, The Hershey Company Corporation
Based on the principles of the Toyota Motor Company, “LEAN” manufacturing is about systematically
eliminating waste from the supply chain and connecting the employee directly to the job of customer satisfaction. Several techniques will be explored including the 5s, SMED/Quick Changeover, Standardized Work, Theory of Constraints, World Class Maintenance and Six Sigma and a variety of concepts including two “key” ones; kaizen and kanban will be described. Reasons why a company should look towards embracing this concept and what drives the successful implementation of LEAN manufacturing will also be addressed.
POLYOL USAGE IN CONFECTIONERY APPLICATIONS
Peter Jamieson, Research Scientist, SPI Polyols, Inc.
This presentation will start off with a general overview of polyols followed by a more in-depth look into handling polyols in the manufacturing plant. Issues addressed may include receiving, storing (bulk and small unit), handling and processing of raw materials, pricing and interactions with other ingredients. How to handle potential problems in the plant, with these products, will also be examined.
KEYNOTE ADDRESS – MEDICINAL, CULTURAL & CULINARY USES OF CHOCOLATE (A 450 YEAR PERSPECTIVE)
Howard-Yana Shapiro, Ph.D., Director, Plant Science, Mars, Incorporated
This year’s Tuesday evening dinner banquet will be highlighted with an educational, yet entertaining presentation on the traditional, sometimes extreme, spiritual and superstitious uses of chocolate throughout history. Through a culmination of field work, library and archive research, interviews and photography, this speaker can now share his extensive research, done in collaboration with Professor Lois Grivetti of UC Davis, into the exciting history of one of the world’s greatest passions – chocolate!
Wednesday, April 13, 2005
Sessions led by moderator Reg Ohlson, Retired
FUNCTIONAL CONFECTIONERY: TO DO OR NOT TO DO
Jeffrey Grant, Vice President of Quality/R&D, Cherrydale Farms, Inc.
The purpose of this presentation is to provide an outline for confectioners who are currently
manufacturing or looking to manufacture functional, confectionery products of any kind. The scope of the discussion will surround the issues of functional confectionery product categories, processing formats, why a confectioner would want to get involved with functional confectionery products, how to
prepare an organization for making these products and key organizational impact considerations. The differences between confectionery and functional food manufacturing, as well as information in regard to conforming to the dietary supplement GMP’s will be provided.
LATIN AMERICAN COCOA OUTLOOK
Robert Peck, Program Coordinator, World Cocoa Foundation
With a variety of trends emerging, Latin America is currently playing a key role in cocoa production, as cocoa in this region has the characteristics of unique flavor and aroma that distinguishes it from other origins. This presentation will focus on the opportunity cocoa has in Latin America to make a difference in household income for rural families and how the research community is working to control and eradicate devastating diseases that are threatening the cocoa crops. An emphasis on why it is important to save the flavors of this region by supporting the farmers, and a look at the ACCESO (Andean Countries Cocoa Export Support Opportunities) for moving from country specific systems, to a more coordinated, regional approach will be presented.
VIVA LA DIFFÉRENCE – THE EVOLUTION OF ORIGIN CHOCOLATE
Gary W. Guittard, President, Guittard Chocolate Company
This presentation will briefly take the audience through the historical evolution of origin chocolate to a more in-depth look at the current market for these “national treasures”. Strengths and limitations of Blends and Single Origins will be addressed as well as standards, labeling and blend percentage issues. Availability, farmer subsidization programs and the efforts to preserve origin integrity will be discussed. A look at how this subject is helping to infuse excitement and dimension into the category, not just from a user point of view, but also from a producer perspective, will also be presented.
THE TRANS FAT REGULATION – IMPLICATIONS AND SOLUTIONS
Jeffrey B. Fine, Director of New Products & Technology, Aarhus United USA
This presentation will begin with a discussion surrounding the definition, basic chemistry and sources of dietary trans fat. The scientific evidence for public health concern over trans fat will be examined, and the latest labeling regulations in the U.S. and around the world will be reviewed. Finally, various approaches available to food manufacturers to eliminate trans fat will be explored, and a market survey of reduced trans food products will be provided.
TROUBLESHOOTING CHOCOLATE AND COATING – HOLLOW, SOLID, ONE-SHOT AND ENROBED ITEMS
Eric Schmoyer, R&D Lab Manager, R.M. Palmer Company
This presentation will focus on identifying quality issues and their possible causes, to help minimize rework and any line or mould problems. Issues with sanitation, decorations, moulding, de-moulding,
vibration, cooling, depositing, center treatment, coating & viscosity which may result in problems such as fat bloom, sugar bloom, dull product, air bubbles, unsatisfactory bottoms, streaks, coarse, grainy texture, center leaks, sticking, spots, fingerprints, marks and weight control will be explored.
The importance of looking at quality parameters that must be controlled by the supplier and communicating with Line Technicians will be discussed.
SPECIAL EVENTS
Sunday, April 10, 2005
PMCA ANNUAL MEMBER GOLF TOURNAMENT
Shot Gun Start - 10:00a.m.
Hershey Golf Club – East Course
RESEARCH COMMITTEE MEETING
2:00p.m. – 4:30p.m.
Wild Rose A (Confection Hall)
EDUCATION COMMITTEE MEETING
11:30a.m. – 1:30p.m.
Magnolia A (Confection Hall)
Monday, April 11, 2005
SUPPLIER EXHIBITION
12:30pm – 5:30pm
Great American Hall
RECEPTION AND DINNER
5:45pm (cash bar)
Chocolate Lobby
6:45pm (dinner)
Chocolate Ballroom
Tuesday, April 12, 2005
PMCA ANNUAL MEMBER MEETING
1:00pm – 1:40pm
Empire A & B (Confection Hall)
ANNUAL PRODUCTION CONFERENCE DINNER
6:00pm (open bar)
Chocolate Lobby
7:00pm (dinner)
Chocolate Ballroom
*Awards ceremony and keynote address by Dr. Howard-Yana Shapiro M&M/Mars
Wednesday, April 13, 2005
PRODUCTION CONFERENCE COMMITTEE MEETING
12:30pm-3:00pm
Cocoa Suite 6
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