The full monty.
There are three different processes for manufacturing filled chocolate.
Shell molding involves the liquid chocolate mass being poured into a cold mold and immediately inverted so that some of the mass pours back out again. A thin layer of solidified chocolate adheres to the inner mold surfaces; this is known as the chocolate shell.
The filling is now poured into this shell and distributed evenly by shaking it. Finally, what will later be the base of the chocolate bar is poured over the top. To make sure that the join is seamless, the rim of the chocolate shell is heated again. Excess chocolate mass is scraped off and the base is smoothed out.
Here, a plunger which is cooled to below freezing is pressed into a mold containing a precisely weighed quantity of chocolate. This distributes the chocolate mass evenly over the mold, creating an evenly shaped chocolate shell. When the shell is firm, the plunger is removed. The filling and base are added as with the shell-molding process.
One Shot depositing
During one-shot depositing, the filling and chocolate are added to the mold simultaneously, on one operation, via two nozzles, the outer one for the chocolate and the inner one for the filling. This manufacturing method only makes sense if the chocolate and filling have very similar viscosities.
Though this is the fastest method and saves space and energy, chocolate produced in this way needs to be cooled more slowly and carefully to avoid hairline cracking or bursting.
To produce our filled RITTER SPORT chocolate varieties, we use the shell-molding process. This is highly flexible and is best suited to adding all our different fillings, such as nuts, yoghurt or marzipan, to our square bars.