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photo location A Guide for Teachers Moulding and Packaging Chocolates Written,

photo location A Guide for Teachers Moulding and Packaging Chocolates Written, illustrated and produced by Tony Mander, June 2001 This support resource was jointly funded from the Minister for the Environment’s Sustainable Management Fund, administered by the Ministry for the Environment, and from the Packaging Council of New Zealand. This material may be freely used for any non-profit purpose. NESTLÉ® is a registered trade mark of Société des Produits Nestlé S.A. Vevey – Switzerland and is used with their kind permission. Contents Page Introduction ........................................................................................................................................................................... 1 Read this first! 1 Using the ‘PAC-IT Teacher Guide’ 1 Pathways to moulding and packaging chocolates 2 1 Moulding and packaging chocolate as a curriculum topic ................................. 3–6 Technology 3, 4 Science 4 Mathematics 5 English 5 Social Studies 6 The Arts 6 Physical Education and Health 6 2 About chocolate ................................................................................................................................................. 7–9 History and production 7 Kinds of chocolate 7, 8 (summary diagram 8) Melting and tempering chocolate 8 Common problems when moulding chocolate 9 3 Melting chocolate for moulding in a classroom ................................................................ 10 4 Moulding chocolate ................................................................................................................................ 11–15 Moulding hints 11 Using ready-made moulds 11 Making your own moulds 11 A: Setting up 12 B: Forming moulds from plastic (polymer) sheet 12 Safety notes 13 Moulding problems 13 Care of moulds 14 Formers for making your own moulds 14 Making chocolate shells for filling 15 Fillings 15 Making hollow chocolates 15 5 Hygiene and food safety .................................................................................................................... 16, 17 Hygiene 16 Assessing risks: HACCP 16 6 Packaging individual “gift” chocolates ....................................................................................... 18 Packaging ready-made chocolates 18 Wrapping 18 Decoration and labelling 18 7 Nets for individual paper and paperboard packages ........................................ 19–25 Package nets 19–25 A PAC-IT support resource: Moulding and packaging chocolate – A guide for teachers 1 Moulding and packaging chocolates A guide for teachers Introduction ●Read this first! Moulding and packaging chocolate is a popular technology activity in years 4–10 classes. This resource aims to support teachers at these levels. Moulding and packaging chocolate is authentic in that hand-made choco- lates are still produced today by skilled chocolatiers, and demonstrates the skills and knowledge required to produce a high-quality product. Unless the teacher is a trained chocolatier (in which case these notes are irrelevant!) the chocolates produced in a classroom are acceptable but can not be called “high-quality hand-made chocolates” as the facilities will be inadequate and there is insufficient time to acquire the required levels of skill, experience and knowledge. This is an important teaching point, as pupils need to appreciate the depth of knowledge, skills and experience required to pro- duce a high-quality technological product. This applies to most technology education activities, as the goal is to generally educate and give pupils technological literacy, not to produce specifically skilled technologists. This topic and its activities allow important concepts to be introduced or reinforced. Although these notes are primarily intended to support further use of the ‘PAC-IT Teacher Guide’, they introduce the whole process of moulding chocolate. Basic information about chocolate and moulding it has been included because a product is needed for packaging and because it illus- trates elements of technological practice. No learning outcomes have been suggested as it is the professional task of teachers to define those best suited to their class over a range of learning areas. Learning outcomes for technol- ogy education are generally defined in these domains: conceptual, procedural, societal and technical. While not introduced until Sections 6 and 7 of these notes, packaging is one of the core topics for this activity as, unless immediately consumed, the moulded chocolates must be packaged for food safety and to maintain the flavour and appearance. Packaging also offers opportunities for considerable extension work. As one key function of packaging is to maintain the best qualities of a product, these notes may assist in obtaining the best product achievable in a typical classroom situation. ●Using the ‘PAC-IT Teacher Guide’ It would be helpful to first read these sections of the ‘PAC-IT Teacher Guide’ (which can be ordered from this website): • Introduction to packaging, pages. 2–4 • Packaging and society, pages 11–13 • Packaging functions, pages 14–24 • Nets of paperboard containers, pages 56–61 • Labelling, pages 115–118 (also see the Australia New Zealand Food Authority website: www.anzfa.govt.nz) If you want your pupils to develop their own packaging, this section would also be useful: • Developing packaging for a product, pages 28–40 This column allows space for your own notes. 2 A PAC-IT support resource: Moulding and packaging chocolate – A guide for teachers Core concepts • Packaging must meet requirements for labelling. • Packaging must be attractive to the consumer. ●Pathways and concepts in moulding and packaging chocolates 1 Making own moulds 2 Ready-made chocolate moulds Process starting points Melting chocolate Products Process stages 3 Ready-made chocolates Finding and preparing a suitable former, or making own former vacuum-forming a mould plastic mould/s setting up a simple chocolate melter, maintaining chocolate in desired condition best quality chocolate for moulding moulding chocolates moulded chocolates packaged chocolates selecting packaging materials, designing and making packaging packages Core concepts • Packaging contains and protects the product from mechanical and chemical damage. • Packaging preserves the product, retaining such qualities as flavours, appearance and texture. Core concepts • Foods require careful handling to ensure safety. • Standard food safety protocol (such as HACCP) are important tools in maintaining food safety. Core concepts • A material has specific properties; some properties may be modified by various treatments. • Achieving required properties requires appropriate techniques. Core concepts • A technologist must be able to identify problems and match solutions. • Knowledge and experience are both required to produce the best product. Core concept • Conditions must be carefully controlled to achieve consistency. Core concepts • Making a vacuum-formed mould requires a former. • Formers for vacuum-forming must meet certain specifications. Topic starting points 1 Technology: Strand C Place of confections in our food traditions, leading to a need/opportunity to produce chocolate confections 3 Technology: Strand B An opportunity to make moulds for hand-made chocolates 2 Technology: Strand C Use of packaged chocolates as personal gifts; chocolate as an ‘energy’ food A PAC-IT support resource: Moulding and packaging chocolate – A guide for teachers 3 1 Moulding and packaging chocolate as a curriculum topic This topic is suitable as a context for meeting objectives in technology in particular, but also in science, mathematics, languages, social studies and the arts. It is a good integrating topic, providing an authentic context for pupils to apply and extend skills and knowledge acquired in other learning areas. Only a very brief summary of elements relevant to selected strands of the essential learning areas in the New Zealand Curriculum have been listed, generally in ascending level order (but only to level 5, as this resource is intended for teachers of years 4–10). Specific outcomes and levels are not identified. This resource is intended to save teacher time in looking up the relevant information. Using ready-made chocolates and packaging them has not been described, although it is an option where only packaging is the focus. ●Technology Core concepts, skills and knowledge • Biotechnology: – Additives and processes: the use of enzymes to produce soft fillings for chocolates (the enzyme is added to the solid filling and slowly digests it to make it soft); source of enzymes (many are extracted from cultures of bacteria). – Cloning technology: a process has been developed to clone cacao trees from cacao flower tissue, although it is not used commercially. Cacao plants grown from seed vary in their yields and disease resistance, so plants with the best characteristics would be selected for cloning. Note that all vegetative forms of reproduction, both natural and human methods (e.g. runners, cuttings, grafting, tissue culture, etc.) are forms of cloning, and used to propagate plants of any origin. • Food technology: – Identifying and retaining desirable food qualities: tempering chocolate to retain the best texture; ingredient ratios in different kinds of choco- lates (see p. 7, 8); packaging to retain flavour and prevent tainting – Food safety: appropriate classroom procedures; HACCP protocols; packaging and labelling – Diagnosing problems: diagnosing causes of undesirable features (streaks, cracks, etc.), taking appropriate action to fix and/or prevent the problem – Attractiveness: making or selecting attractive shapes for formers; using different chocolate colours to add interest to the shapes – Food chemistry: physical properties of chocolate (e.g. melting points); chemistry of fats, enzymes, etc. in chocolate. • Materials technology: – Moulding: how a former is used to make a mould in which a liquid can be poured to solidify in the shape of the former – Properties of materials: how a thermoplastic plastic material becomes plastic (i.e. can be shaped when softened), mouldable properties of chocolate; identifying the required properties of the former (e.g. heat resistant, leaves no residue on the plastic) – Properties of packaging materials: impermeability of aluminium foil; ability of paperboard to hold a fold; qualities of inks and printing on to paperboard; etc. – Adhesives: choice and use uploads/Geographie/ choc-guide.pdf