So I've been experiencing cracks on the foot of my bonbons that I've been unable to find the cause of, hoping to reach out to the community to get to the bottom of this costly problem.
I work for a small chocolate company that makes our own bean to bar couverture. We use a continuous tempering machine with enrobing belt attachment.
The process: ganache is made and then piped into round silicone molds, which are then footed with tempered chocolate before being placed in the freezer until frozen enough to pop out of the molds. They are then set up right and left to thaw and dry out overnight on a equipped with fans aimed at the bonbons. The next day we send the bonbons through the enrober, and then they are transferred to a speed rack to set up, either at room temp (generally around 68-70 degrees F) or in a homemade cooling cabinet (an insulated box equipped with an air conditioner + dehumidifier + fans) that generally fluctuates between 50-56 degrees F (I know, large range).
Problems occur with both milk and dark couverture, with bonbons kept at room temp or in cabinet, thickness of foot doesn't seem to make a difference (we've tried thicker and thinner). Crack doesn't immediately appear; it usually takes a couple of minutes after being completely set before showing. It looks as though the foot is popping out, cause a hairline crack between the shell and the foot. I've attached pictures. You'll notice in the photos, that when the bonbon is cut in half, the foot separates from the shell pretty significantly.
Thoughts? Suggestions? Similar experiences?