BPA-free chocolate molds

Polycarbonate chocolate molds contain BPA

Chocolate molds are often made of polycarbonate, as this material is durable and does not break or deform even with continuous use. The smooth material surface is also ideal for producing high-quality chocolate products. However, polycarbonate is made from bisphenol A (BPA). When the EU ban on BPA comes into force, the chocolate industry will therefore have to switch to new materials for chocolate molds in the long term.

Criteria for suitable chocolate mold materials

A suitable material for chocolate molds must meet a variety of requirements. During operation, this includes the interaction between the chocolate mold, chocolate mass and production system, taking into account the relevant process parameters. Equally important is the complex interaction of all stakeholders involved along the entire value chain, from polymer manufacturers to mold suppliers, suppliers of mold washing systems and cleaning agents through to chocolate manufacturers.

The aim of the research project is to define the performance criteria for the material specification for the entire service life of the molds while complying with the guidelines for contact with food. Important factors to be considered are:

• High impact resistance for a long service life
• Resistance to greasy chocolate masses and cleaning agents
• Good thermal conductivity for efficient chocolate processing
  
• Optimum surface properties to ensure easy release of the chocolate
• High flexural rigidity for large molds
  

Factors such as cost, sustainability, material availability, quality of the chocolate product, toxicological concerns, food safety (foreign bodies due to breakage) and shelf life or storability of the mold also play a role.

From material to chocolate - the Fraunhofer IVV combines all expertise

The Fraunhofer IVV combines all the necessary expertise to address the challenges associated with BPA-free chocolate molds in a holistic manner. This brings together technological excellence, practical research approaches and comprehensive industry knowledge:

• Material development: Development and evaluation of suitable plastic materials including small-scale tests in the injection molding process
  
• Food compliance: Many years of expertise in testing and ensuring the conformity of food contact materials
  
• Chocolate technology: Sound know-how in the processing of chocolate and its requirements for molding materials
  
• Recycling: Holistic view of the material input, also with regard to recycling and sustainability
  
• Digitization: Comprehensive digital solutions from automated optical quality monitoring to VR-based training for operating personnel
• Plant efficiency / OEE: Professional process and efficiency analyses of processing plants to increase OEE

Thanks to the interdisciplinary orientation of the Fraunhofer IVV, practical and future-proof solutions can be developed for the chocolate industry and for SMEs in particular.