Manufacture

Marzipan- produced with tradition

Rotating open copper kettles 

It is one of those methods of production that harmonise tradition and quality: the roasting boiler procedure. The marzipan is roasted in open, rotating copper roasting boilers. This method gives the marzipan its unique, incomparable taste. And: the Lübecker Marzipan-Fabrik is one of the last marzipan manufacturers to use this procedure and thus attain the uniqueness of Lübeck Marzipan.

 However, before the marzipan can be produced, the raw, brown almonds naturally must be processed. They are cleaned and then blanched with hot water, so that the loosened brown seed coating can be removed in husking machines with rotating sets of rubber rolls. Electronic sorting machines remove faulty almonds, while two additional, specially trained employees remove any remaining faulty almonds manually. Naturally, there is a recipe for every marzipan production. This recipe, which is subject to strict rules, is programmed into the computer-controlled production. In accordance with this recipe the almonds are automatically added, pre-crushed and mixed together with sugar and water.

 

Only then does the tradition, which is over 100 years old, come into operation, after the pre-crushed mixture of almonds, sugar and water is finely ground by two whetted sets of granite rolls, working in opposite directions. The granite rolls give the marzipan a slightly fibrous structure for the right kind of "bite". Then the mixture is heated in the open, rotating copper roasting boilers. Experienced master roasters guarantee an even, high quality roasting of the raw marzipan mixture. After the roasting, the raw marzipan mixture is cooled with sterile air, shaped into blocks of 12.5 kg and packed in foil. The packed blocks are cooled in cold storage to around 16°C within a few hours, so that the valuable almond aroma is not damaged by an excessively slow cooling procedure with longer extremes of temperature. The product quality is monitored during manufacture by a well equipped quality control laboratory, also from a microbiological perspective.

 

  

Nougat- the finest molten enjoyment

Conche 

At first it was merely an idea - back then, when chocolate was mixed with hazelnut paste. Today, hazelnut nougat is just as much a speciality as almond nougat, and one can no longer imagine the confectionary market without them. The fact that a difficult process is necessary for the manufacture of this fine nougat mixture in order to reach the very best quality is demonstrated every day in the nougat production at Lubeca.

 

The basis of nougat variations are formed by hazelnut or almond paste, which we manufacture from freshly roasted hazelnut kernels or almonds. Depending on the type of nougat and the desired degree of roasting, the dried fruit is roasted to degrees ranging from light to dark brown and then ground to a paste by fly cutter mills. The roasting is done in a hot stream of air in a fluidised bed procedure, whereby the nuts are roasted individually and not as a compact mass, as is the case with drum roasters. This produces a more even heat transfer across the entire surface. Important factors for the differently defined degrees of roasting are roast duration and roast temperature.  

The fine or molten quality of the nougat is achieved by rolling it finely with five-roll refiners. Sugar, coating and cocoa butter, where required also milk and cream powder are added in a computer-controlled process in accordance with the respective recipe. The homogeneity and the consistency of the nougat is achieved by the subsequent conching process in 3 to 6 tonne plants. The filling into buckets or boxes is done by modern heat-treating machine, with which the desired consistency and firmness of the nougat is created.

 

 

Chocolate coatings - the perfection of taste

Couverture is spilled 

Taste, melting quality and appearance in perfection - Lubeca's chocolate coatings deliver what they promise. The renowned excellent quality is determined by knowledge that has grown over decades.

 

 

Select cocoa growths from the best plantations in South America, Africa and the Caribbean are added in a computer-controlled procedure to other raw materials such as cocoa butter, whole milk powder, sugar and natural vanilla extract in accordance with the respective recipe and then homogenised in the mixer. Fine rolling operations with two-roll and five-roll refiners lead to a refining of the grain from around 16 thousandth of a millimetre, thus transforming into the popular fine molten chocolate coating from Lubeca. While conching for up to 48 hours, unwanted aroma materials such as acids disappear. Once poured into 2.5 kg forms, the nougat then passes through a cooling tunnel and is automatically packaged after it has been shaped into bars.
The entire manufacturing process is monitored by the quality control laboratory. Similar to the marzipan and nougat manufacture, HACCP systems (Hazard Analysis Critical Control Point) are also used here to guarantee a high degree of production safety. This includes, for example, microbiological examinations for any relevant germs including salmonella and the carrying out of sensory tests for deviations in taste.

 

 

 

Hazelnut and almond preparations - quality that can be seen

Slices machine 

Regular almond chips without any broken-off tips, large planed slices of hazelnut and almond with few cracks, halved almonds for decorating, selected by hand - our preparations are of the highest quality, as our customers constantly confirm.

 

 

Calibrated almonds and hazelnut kernels of selected origin are the raw materials that we use for our preparations. Only kernels of this provenance and of a defined size (e.g. Californian almonds Nonpareil or Carmel of at least 27/30 size or Levantine hazelnut kernels from the Black Sea coast with a size of 13-15 mm) are considered. Because almonds and hazelnut kernels are relatively brittle, they must be conditioned with moisture and heat. Only then can they be cut into especially thin slices of 0.45 mm. These planed slices are not only of high quality optically, but also provide a high yield for covering confectionary and baked products. Furthermore, the large surface means that the almond taste is even more prominent.


Conditioning, slicing, grating, chopping and cutting - we also use these methods in manufacturing almond chips and other preparations. For this purpose we maintain a modern selection of machines with permanently whetted and sharpened tools. The water added in the conditioning process is reduced again after processing in a drier, so that all products delivered have a maximum moisture content of only 5%. The dried almond and hazelnut preparations are then sieved gently with fine sieves, so that only goods that meet the specifications with relatively few broken pieces are packaged and supplied.